A

fluidised catalytic cracking unit

(FCCU) must operate at its optimal
reactor temperature with minimal
variability to meet yield and feed-rate
objectives. Conclusions drawn from a
pressure survey at Farmlands Coffeyville
refinery explained why the FCCU was
unable to maintain its desired reactor
outlet temperature. Pressure data showed
that the overflow well had a low catalyst
level, suggesting that catalyst flow from
the reactor was limited. Pressure data
taken from the catalyst stripper and spent
catalyst standpipe identified the
constricted area, and debris was removed
during the next shutdown.
Troubleshooting
Farmland Industries operates a 28 000-
barrel per day FCC at its Coffeyville
refinery. The companys FCCU is an
Exxon Flexicracker constructed in 1979.
Feedstock consists of virgin vacuum and
coker gas oils. A generalised schematic of
the FCCU is shown in Figure 1.
The FCCU is a pressure-balanced
operation like many Exxon FCCU
designs. Catalyst circulation control in a
pressure-balanced unit is very different to
a traditional slide valve-controlled
operation. These differences must be
considered when troubleshooting and
during unit optimisation. A discussion of
pressure-balanced versus common slide
valve-controlled operations is presented
later.
Farmland was finding it difficult to
achieve and maintain the desired riser
outlet temperature. The feed temperature
was increased within the constraints of
the charge heater, and the stripping
steam rate was reduced in order to
increase regenerator and reactor
temperatures with limited success.
Operating at low stripping steam rates
was undesirable and economics strongly
supported operating at higher riser outlet
temperatures.
Farmland and Davison personnel
planned a single-gauge pressure survey of
the entire FCC catalyst circulation loop
in an effort to determine why catalyst
circulation was not
sufficient to reach and
maintain the desired
reactor temperature.
The regenerator and
overflow well was the
first area of focus.
Figure 2 shows the
pressure data taken
along the regenerator
and overflow well.
Determining the
catalyst level in the
overflow well level is
key to troubleshooting
a pressure-balanced
operation. The
pressure differential
between the dilute
phase of the
regenerator and the
bottom of the overflow
well was used to
compute the overflow
well catalyst level.
Assuming a catalyst
density of 38lbm/ft
3
, a
catalyst height of only
5.7ft inside the
overflow well was
calculated by the equation:
= (30.028.5) lb
f
/in
2
144in
2
/ft
2
/ (38lb
m
/ft
3
)
= 5.7ft.
The catalyst level inside the overflow
well was approximately 35ft below the
top of the overflow well. Some 30ft of
available overflow well length was
unused. This information suggested that
catalyst flow to the regenerator from the
reactor/stripper might be restricted.
Attention was then focused on the
spent catalyst transfer system. Figure 3
shows the pressure data taken at the
bottom of the catalyst stripper and along
the spent catalyst standpipe. Rather than
building a pressure head from the
bottom of the stripper to the top of the
spent catalyst standpipe, pressure
dropped from 3430.5psig.
A large pressure drop of 11psi (pounds
Catalyst circulation in a
pressure-balanced FCCU
Significant improvements have been made in FCC reactor temperature control
at Farmlands Coffeyville refinery. Data interpretation are presented along with
advice to consider when troubleshooting a pressure-balanced FCCU operation
David Spires Farmland Industries Inc, Coffeyville, Kansas, USA
David Hunt Davison Catalysts, Houston, Texas, USA
PTQ REVAMPS & OPERATIONS
36
Figure 1 General elevation sketch of the Farmland FCCU
Outerflow
well
Spent catalyst
standpipe
Regenerated
catalyst J-bend
Regenerator
Reactor
Overflow well
Regenerator
28.5
30.0
5.7 ft
Figure 2 Regenerator and overflow well
pressure survey
h
per square inch) was also noted across
the upper spent catalyst slide valve. This
was unexpected, since the catalyst slide
valve was operating nearly 100% open. A
pressure survey along the reactor riser
revealed an expected riser pressure drop
of approximately 4psi.
It was construed from this data that
significant restrictions existed along the
bottom of the stripper, the spent catalyst
standpipe and perhaps in the upper slide
valve. To increase catalyst circulation,
Davison recommended that Farmland:
Reduce regenerator pressure, as this
would help increase catalyst circulation
and increase the catalyst level in the
overflow well
Conduct gamma scans along the base
of the stripper and spent catalyst
standpipe to confirm location of the
potential obstruction.
Since these pressure survey results
were so convincing, plus the fact that the
unit would come down for turnaround
within a few months, it was decided to
forego gamma scan testing. Instead,
Farmland prepared to remove coke or
possibly refractory from the stripper,
spent catalyst standpipe and slide valve
during the turnaround.
During the turnaround, Farmland
discovered a large coke restriction at
the bottom of the catalyst stripper, as
depicted in Figure 3. A mass of coke
had become lodged in the debris cage
at the base of the catalyst stripper.
Smaller pieces of coke and refractory
were also noted in the spent catalyst
standpipe. After the turnaround was
complete, Farmland could maintain
the target reactor temperature.
This simple pressure survey
explained why the unit was unable to
reach the desired reactor outlet
temperature and isolated the specific
area of catalyst obstruction. Data
collection and interpretation were
conducted in a single day.
Troubleshooting catalyst
circulation
Catalyst overflow well level and
stability are key to understanding
any catalyst circulation shortcoming
in a pressure-balanced operation.
Level in an overflow well can
increase to 510ft below the top of
the overflow well while still
maintaining operational flexibility and
control. A low catalyst level in the
overflow well confirms a low catalyst
circulation rate and suggests catalyst flow
from the reactor may be limiting, as was
the case at Farmland. A high catalyst level
in the overflow well level may suggest:
High pressure drop or obstruction
along the riser or regenerated catalyst
transfer lines
Poor pressure head build-up along the
regenerated catalyst standpipe
High catalyst circulation rate reaching
the capacity of the circulation system.
In the case where the overflow well
level is high, the operator may consider
the following to increase catalyst
circulation, improve circulation stability
and/or increase charge rate to the unit:
Increase fluidisation steam or fuel gas
rates along the transfer lines
Confirm that the correct amount of
aeration medium is being added to the
regenerated catalyst standpipe and adjust
as necessary. Those techniques have been
previously published
Raise regenerator pressure relative to
reactor pressure. (This will slow catalyst
circulation and lower the catalyst level in
the overflow well.) Increase catalyst
activity to maintain unit conversion.
An oscillating overflow well level can
result in a fluctuating reactor pressure
and reactor temperature. This condition
might be due to the following:
Defluidised catalyst entering the
overflow well level or catalyst
defluidising in the overflow well
Bubbles rising from the regenerated
catalyst standpipe blocking catalyst flow
Slip-stick flow in the regenerated
catalyst standpipe.
Resolution of this type of problem is
likely be case-specific and requires a
detailed engineering review of the FCCU.
Pressure balance vs
slide valve control
Catalyst circulation is independently
controlled in a pressure-balanced
operation as opposed to a slide-valve
operation, where it is a dependent
variable. Reactor/regenerator differential
pressure is typically used to control
circulation in a pressure-balanced
operation, where decreasing the
regenerator pressure relative to the
reactor will increase catalyst circulation
rate. Table 1 describes several control
differences between pressure-balanced
and slide valve-controlled units.
Catalyst circulation rate in an Exxon
Model IV pressure-balanced unit can also
be influenced by the control air blower
rate and transfer line fluidisation rates.
In a pressure-balanced operation, the
catalyst level in the overflow well is
variable, depending on the reactor/
regenerator pressure differential and
resulting catalyst circulation rate. A
higher catalyst circulation rate will
generally require a higher catalyst level in
the overflow well level. Reactor catalyst
level builds over time as fresh catalyst is
added to the unit, while regenerator level
is constant and equal to the top of the
overflow well level. Regenerated and
spent catalyst slide valves normally
operate near 100% open in pressure-
balanced operations and are generally
only throttled during start-up, shutdown
and upset conditions.
David A Hunt is FCC technical service
manager, Davison Catalysts, Houston
Texas. He has over ten years of FCC
experience focusing on process design,
proprietary equipment technologies,
troubleshooting and catalysts applications.
He is currently responsible for FCC technical
service activities in North America.
E-mail: david.hunt@grace.com
Nomenclature
g Acceleration constant, ft/s
2
g
c
Conversion constant lb
m
/lb
f
ft/s
2
h
ofw
Catalyst height inside the overflow well, ft
P
ofw
Pressure differential across the overflow
well, lb
f
/in
2
p
ofw
Catalyst density in the overflow well,
lb
m
/ft
3
PTQ REVAMPS & OPERATIONS
37
Parameter Slide valve control Pressure balance control
Reactor temperature Independent variable Dependent variable
Catalyst circulation rate Dependent variable Independent variable
Feed temperature Higher feed temperature Higher temperature feed
will decrease cat/oil at temperature will increase reactor
constant reactor temperature temperature at constant cat/oil
Debris likely present
in the upper spent
catalyst slide valve
Coke deposits
found during
shutdown
Regenerator
Spent catalyst
stripper
34.0
23.0
34.0
30.5
Figure 3 Stripper and spent catalyst
standpipe pressure survey
Control differences between pressure-balanced and slide valve-controlled units
Table 1