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4.0 Guideline:
4.1 CCR Circulation Reduction
The CCR rate reduction will be done after CCR burn temperature
profiles are stable, at least for the past 24hr. RIT adjustment should be
avoided as much as possible to ensure no unexpected coke batches
entering the Regenerator. The rate reduction should be stopped if any
abnormal temperature rise is noted at either TZ or DZ upon rate
reduction or on the next rate reduction. Reduction of CCR circulation
rate is expected to shift the peak temperature to the top, but this is only
temporary as the coke build up would shift down the profile again.
This activity should be done at ONLY 5% REDUCTION EVERY 12H to
enable sufficient time for proper observation of temperature changes and
change in O2 demand.
4.1.1 Ensure all required readings are noted in the attached table before
first CCR circulation rate reduction is done.
4.1.2 Oleflex process should be stable and no RIT or H2/HC adjustment
should be done prior to or during the exercise.
4.1.3 Ensure the O2 demand valve, AV-7001 is stable and not trending
up or down significantly
4.1.4 Reduce CCR rate by 5% at the beginning of the Shift if all other
CCR parameters are stable.
4.1.5 Observe the process for the next 12 hours and fill in the parameters
table at the end of the 12 hours.
4.1.6 Adjust O2 within controllable range of 0.6-0.8 mol% if required,
else leave the setting as status-quo. The aim is to keep O2 at lower
range to allow the coke front to move lower into the tower. If AV7001 opening increases by 5-10% higher, introduce Upper Air into
the tower to maintain the normal valve output.
4.1.7 Monitor closely the changes in the TZ and DZ temperatures. If
temperature in the DZ increases by 5-10 degC, this may indicate
coke travel into DZ. Increase O2 setting by 0.05-0.1 mol%, and
temporarily decrease CCR rate further to slow down the coke
movement. This would temporarily assist coke to burn at BZ
instead of TZ or DZ. Adjust O2 higher if required based on TZ or
DZ temperature. In worst case, the operation should be switched to
Black Burn mode and later Dual Zone Burning mode. This would
be required if DZ temperature exceeds by 15 degC.
4.1.8 If operation is switched to Black Burn or Dual Zone Burning
mode, then do not reduce CCR rate any further until White Burn
mode is re-established.
4.1.9 Sample both Regenerated and Spent Catalyst coke every 8h and
record in the table provided.
4.1.10 As long as Spent Catalyst coke does not exceed 3.5 wt%, continue
reducing CCR circulation rate every 12hrs. The steps are repeated
as long the burning remains within BZ, and no significant increase
in temperature is observed at TZ or DZ. Monitor the Regeneration
Tower pressure closely, since air demand would rise when coke
builds up more, but AV-7001 may open higher and reduce the
tower pressure.
4.1.11 The final CCR circulation rate should be around 900 lbs/hr as long
Spent Catalyst coke does not exceed 3.5 wt%. Else return to
previous circulation rate if coke results indicate higher than 3.5 wt
%. However do not increase CCR rate abruptly without adjusting
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