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223 views

Fccu PDF

Uploaded by

Sumit Kaushik
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Application Guide HPG-19b

Fluid Catalytic Cracking


Slurry Oil Clarification

FCC Slurry Oil


Reactor

Gas

Regenerator
Light Cycle Oil
FCC
Unit
Intermediate Cycle Oil

Heavy Cycle Oil


Clean
Heavy
Cycle Oil
Pall Backwash
Filter System
Air
Feed
Concentrated Slurry Recycle

Process Description
Fluid Catalytic Cracking (FCC) produces high octane
gasoline, C3/C4 olefins and isobutane by the catalytic
cracking of heavy gas oils in a fluid bed reactor. The
primary product separation is carried out in a fractionator
which produces gas as the overhead products, gasoline
and heavier gas oils as side draw-off products and heavy
cycle gas oil as the bottoms product. This bottoms
stream contains the catalyst not collected by the cyclones
in the reactor, and is sometimes referred to as slurry oil.
Need
The solids concentration of slurry oil typically exceeds
1500 ppm, which must be lowered substantially before
the oil can be sold. Typically, slurry oil is disposed one of
three ways:
1. It is most commonly blended into the No. 6 fuel oil
pool, also known as bunker C fuel. The typical
alumina concentration permitted in No. 6 fuel oil is 250
ppm, which originates solely from the catalyst in the
slurry oil component. To meet this specification,
refineries often add lighter, solids-free saleable
products to dilute the slurry oil. This limits the total
revenue capability of the refinery since No. 6 fuel oil is
a relatively low price product.
2. It can be used as a feedstock to a coker unit or a
hydrocracker. This converts a portion of the slurry oil

to lighter, higher value products, but it does not


remove the catalyst from the system.
3. It can be sold as a feedstock to carbon black
manufacturers. Slurry oil with a maximum solids
content of 100 ppm, can yield a selling price of
$1-2/barrel higher than fuel oil.
Solution
The Pall solution is to filter the slurry oil to reduce its solids
content to an acceptable level. The clarified oil can then
be sold to carbon black producers at a premium, blended
into the No. 6 fuel oil pool without exceeding the alumina
specification, or as a boiler fuel without causing fuel nozzle
erosion. The solids are discharged from the filter in a
highly concentrated form to facilitate disposal, or minimize
recycled volume. This approach is economically attractive
since it increases the refinery's income and minimizes the
waste disposal problem. When compared to conventional
separators utilized by refineries, Pall filters are substantially
lower in both capital and operating costs.
Pilot Testing
Pall Corporation demonstrated the technical feasibility of
filtering slurry oil by side stream testing under actual
operating conditions. These tests have been successfully
carried out at several refineries. Rigimesh grade K filter
medium was used in a test filter unit to lower the solids

concentration of the stream from an average of 1500 ppm


to 100 ppm. This represented a 93% removal by weight
of the very fine catalyst particles.
The particle size distribution of the catalyst is highly
variable depending on the FCC unit and fractionator
throughput and operating conditions. The following is a
typical size distribution:
Diameter (m)
(actual particle count)

% by number

1-5

30

5-15

55

15-25

10

25-50

5
<0.3

>50

Flow densities of 0.3 to 1.0 gpm/ft2 were used in the


tests. The typical process conditions were:
Temperature:
Fluid Viscosity:
Fluid Density:
Pressure Drop Prior to Backwash:
Equilibrium Pressure Drop:
Cycle Time Between Backwashes:

400-650F
0.8-4 cp
0 - 10 API
20 psid
<4 psid
2-3 hours

Using Pall's bump and settle backwash technique, the


solids concentration in the discharged material (backwash
waste stream) was approximately 2.5 lb/gal (about 30%
by weight solids). The filter showed no tendency to blind
through repeated backwash cycles.

2200 Northern Boulevard


East Hills, New York 11548-1289

Applications
Every refinery with an FCC unit has this need to highly
concentrate solids in the slurry oil into a small volume for
easy recycle, while maximizing the recovery of saleable
clarified oil. The backwash waste stream contains
approximately 30% by weight catalyst, allowing easy
recycle to the riser of the FCC unit. The clarified oil from
the backwash filter has a sufficiently low solids and
alumina content to be sold at a $1-2/barrel premium as
carbon black feedstock. Alternately, it can be blended
into the No. 6 fuel oil pool without exceeding the alumina
specification for No. 6 fuel oil. This removes the need for
blending lighter, higher value products into the No. 6 fuel
oil, maximizing the total revenue of the refinery. In
refineries where slurry oil is used as feedstock to a coker,
hydrocracker or visbreaker unit, filtration of the slurry oil
prior to the unit will minimize the operating problems
caused by the presence of high solids concentrations in
the feeds to these units. The clarified oil can also be used
as a boiler fuel without causing fuel nozzle erosion.
In each application, the appropriate filter grade will be
selected for the required solids removal. The filter sizing
and operation can be tailored to satisfy the specific
requirements of the refinery. Automated control of multivessel backwash filtration units provides reliable,
continuous operation.
Reference Bulletin
PALL POROUS METAL FILTERS FOR SOLIDS
SEPARATION IN LIQUID AND GAS STREAMS (PSS-740)

888.873.7255 toll free


516.484.5400 phone
516.484.0364 fax
800.664.7255 Select-A-FAX*
Copyright 1990,1999, Pall Corporation. Pall,
are trademarks of Pall Corporation. indicates a Pall trademark
registered in the USA. *Select-A-FAX is a registered trademark of CyberData, Inc.

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