Fluid Catalytic Cracking Handbook

An Expert Guide to the Practical Operation, Design, and Optimization of FCC Units

4th Edition - April 16, 2020
Imprint: Butterworth-Heinemann
Author: Reza Sadeghbeigi
Language: English
Hardback ISBN:
9 7 8 - 0 - 1 2 - 8 1 2 6 6 3 - 9
eBook ISBN:
9 7 8 - 0 - 1 2 - 8 1 2 6 6 4 - 6

Fluid Catalytic Cracking Handbook: An Expert Guide to the Practical Operation, Design, and Optimization of FCC Units, Fourth Edition, enables readers to maximize the profitabi… Read more

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Fluid Catalytic Cracking Handbook: An Expert Guide to the Practical Operation, Design, and Optimization of FCC Units, Fourth Edition, enables readers to maximize the profitability and reliability of fluid catalytic cracking operations by covering all stages of FCC, including their design, operation, troubleshooting and optimization. It includes valuable chapters on FCC Main Fractionator and Gas Plant and Process Engineering Tools that provide engineers with the relevant tools they need to fully optimize processes and operations. This book presents technologies and processes that will improve the profitability and reliability of FCC units, along with lessons from Mr. Sadeghbeigi’s 30 years of field experience.

The book provides a valuable reference for experienced engineers, but is also an ideal reference for those who are developing their skills and knowledge base.

Cover image
Title page
Table of Contents
Copyright
Dedication
About the Author
Preface to the Fourth Edition
Chapter 1. Fluid catalytic cracking process description—converter section
1.1. Feed preheat section
1.2. Converter section
1.3. Regenerator flue gas section
Summary
Chapter 2. Process description main fractionator, gas plant and product treating sections
2.1. Main fractionator tower
2.2. Gas plant
2.3. Water wash system
2.4. Treating facilities
2.5. Ultra low sulfur gasoline (ULSG)
Summary
Chapter 3. Process control instrumentation
3.1. FCCU converter operating variables
3.2. Process control instrumentations
3.3. Feed diversion/Shutdown matrix
3.4. Advance process control (APC)
Summary
Chapter 4. FCC feed characterization
4.1. Hydrocarbon classification
4.2. Feedstock properties
4.3. Feedstock Impurities
4.4. Metals
4.5. Empirical correlations
4.6. Benefits of hydroprocessing
Summary
Chapter 5. FCC catalysts
5.1. Catalyst components
5.2. Matrix
5.3. Filler and binder
5.4. Catalyst manufacturing techniques
5.5. Fresh catalyst physical and chemical properties
5.6. Equilibrium catalyst analysis
5.7. Catalyst management
5.8. Catalyst evaluation
Summary
Chapter 6. Catalyst and feed additives
6.1. CO combustion promoter
6.2. SOX additive
6.3. NOx additive
6.4. ZSM-5 additive
6.5. Metal passivation
6.6. Bottoms cracking additive
Summary
Chapter 7. Chemistry of FCC reactions
7.1. Thermal cracking
7.2. Catalytic cracking
7.3. Other reactions
7.4. Thermodynamic aspects
Summary
Chapter 8. Unit monitoring and control
8.1. Material balance
8.2. Testing methods
8.3. Recommended procedures for conducting a test run
8.4. Case study
8.5. Coke yield calculations
8.6. Component yield
8.7. Heat balance
8.8. Analysis of results
8.9. Pressure balance
Summary
Chapter 9. Products and economics
9.1. FCC products
9.2. Gasoline
9.3. Light cycle oil
9.4. Heavy cycle oil and decanted oil
9.5. Coke
9.6. FCC economics
Summary
Chapter 10. Effective project execution and management
10.1. Project management – FCCU Revamp
10.2. Useful tips for a successful project execution
Chapter 11. Refractory lining systems
11.1. Refractory materials
11.2. Use of stainless steel fibers in refractory
11.3. Types of refractory
11.4. Mortar (refractory)
11.5. Plastic refractories/Ram mixes
11.6. Refractory physical properties
11.7. Anchors
11.8. Dual layer anchoring
11.9. Anchor patterns
11.10. Designing refractory lining systems
11.11. Choice of anchoring
11.12. Application techniques
11.13. Plastic refractory
11.14. Quality control program
11.15. Dryout of refractory linings
11.16. Examples of refractory systems in FCC units
Summary
Chapter 12. Process and mechanical design guidelines for FCC equipment
12.1. FCC catalyst quality
12.2. Higher-temperature operation
12.3. Refractory quality
12.4. More competitive refining industry
Summary
Chapter 13. Troubleshooting
13.1. Several general guidelines for effective troubleshooting
13.2. Key aspects of FCC catalyst physical properties
13.3. Fundamentals of catalyst circulation
13.4. Catalyst losses
13.5. Coking/fouling
13.6. Increase in afterburn
13.7. Hot gas expanders
13.8. Flow reversal
Summary
Chapter 14. Optimization and debottlenecking
14.1. Introduction
14.2. Approach to optimization
14.3. Improving FCC profitability through proven technologies
14.4. Debottlenecking
14.5. Reactor/regenerator structure
14.6. Debottlenecking main fractionator and gas plant
14.7. Instrumentation
14.8. Utilities/off-sites
14.9. Steam/boiler feed water
14.10. Sour water/amine/sulfur plant
14.11. Relief system
14.12. Fuel system
Summary
Chapter 15. Emissions
15.1. New Source Performance Standards
15.2. Maximum Achievable Control Technology (MACT II)
15.3. EPA consent decrees
15.4. Control options
15.5. Particulate matter
15.6. NOx
Summary
Chapter 16. Residue and deep hydrotreated feedstock processing
16.1. Residue cracking
16.2. RFCC technology offerings
16.3. Operational and mechanical reliability
16.4. Operational impacts of residue feedstocks
16.5. Processing “deep” hydrotreated feedstock
Summary
Chapter 17. Biofuels
17.1. Greenhouse gas (GHG) emissions
17.2. United States Renewable Fuel Standard
17.3. Renewable identification numbers (RINs)
17.4. Ethanol (C2H5OH)
17.5. Biodiesel
17.6. Renewable diesel
17.7. Co-processing of biogenic feedstocks in FCC unit
17.8. Renewable jet fuel
17.9. Pyrolysis
Appendix 1. Temperature variation of liquid viscosity
Appendix 2. Correction to volumetric average boiling point
Appendix 3. Total correlations
Appendix 4. n–d–M correlations
Appendix 5. Estimation of molecular weight of petroleum oils from viscosity measurements
Appendix 6. Kinematic viscosity to Saybolt universal viscosity
Appendix 7. API correlations
Appendix 8. Definitions of fluidization terms
Appendix 9. Conversion of ASTM 50% point to TBP 50% point temperature
Appendix 10. Determination of TBP cut points from ASTM D86
Appendix 11. Nominal pipe sizes
Appendix 12. Conversion factors
Glossary
Index

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Fluid Catalytic Cracking Handbook

An Expert Guide to the Practical Operation, Design, and Optimization of FCC Units

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Reza Sadeghbeigi

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