Fluidized Catalytic Cracking Unit

(FCCU) Overview
(DTA & SEZ)
Brief on Jamnagar Manufacturing Division
JMD
• JMD have two refinery called DTA refinery (Domestic Tariff Area)
commissioned in 1999 & SEZ Refinery (Special Economic Zone)
commissioned in 2008.Combining together Reliance Jamnagar Refinery
Complex becomes the world’s largest refinery complex in any single
location.
• This refinery has crude processing base capacity of 660 KBPSD (DTA) and
580 KBPSD (SEZ) or 1.24 Million Barrels per day.
• This Refinery is basically intended to cater to the ever increasing demand of
clean fuels in overseas market and provide backward integration to
Reliance’s own petrochemical plants by producing feed stock for PP. Both
these Refineries, strategically located at Jamnagar in West Coast of India,
is primarily, to process crude oil supplied from any part of the world.
• This Refinery complex besides having the primary processing units
CDU/VDU includes secondary processing units like Fluidized Catalytic
Cracker (FCC), Coker, CFP, Alkylation, Platformer, PP, Hydro- treaters,
Meroxes and Sulfur recovery.
 Units Primary Objective
JMD
Crude Distillers Mother Unit - Primary separation by distillation; gives virgin products

Coker Thermal cracking of Vacuum Residue to make Distillate product and Coke

VGOHT FCC feed preparation , removing impurities

FCC Catalytic cracking of VGOHT to make Propylene, LPG, LCO & CSO

PRU Recover Valuable Propylene from Unsat LPG

Unsat LPG Merox Remove Mercaptan Sulfur from C3/C4

Polypropylene Polymer grade PP

Alkylation( of I butane and butylene ) Alkylation of FCC C4 to make premiumGasolene additive

Spent Acid Regeneration ( SAR ) Regenerating spent acid of Alkylation (Sulfuric acid used as Catalyst)

Butamer Isomerising n-butane to i-butane to makeup shortfall for Alkylation

Scanfiner Hydrotreating FCC heavy gasolene to produce 10 ppm Sulfur Gasolene

Extractive Merox Treating FCC light Gasolene to 10 ppm Sulfur Gasolene

Diesel Hydro desulphurisation Coker & VGOHT Diesel to 10 ppm Sulfur Diesel

LCO Hydrocracker Hydrocracking of FCC LCO to make Aromatic heavy Naphtha for Platformer

Post Treat Unit ( PTU) Aromatic saturation of LCOHC Residue/ Diesel to make Euro V Diesel

Kero Hydrotreating Desulfurization of light Kero to produce Jet fuel

Heavy Naphtha Hydrotreating ( HNHT ) Sulfur reduction of Straight Naphtha to 0.5 ppm Sulfur for platformer feed

Coker Naphtha Hydrotreating ( CNHT ) Sulfur reduction of Coker Naphtha to 0.5 ppm Sulfur for platformer feed

Platforming Reforming of Heavy Naphtha into aromatic rich for Gasolene blending

Sat LPG Merox Treating C3/C4 of CDU/VDU for alkylation feed

 Configuration - Capacity – Licensors (DTA)
JMD
Sr. No. Process Unit Unit No. Capacity Technology
1 CDU/VDU 660 KBPSD UOP/Shell
311 & 312

2 VGOHT 361 & 362 209 KBPSD UOP

3 DHT 351 & 352 200 KBPSD UOP
4 KHT 265 30 KBPSD UOP
5 CNHT 222 25 KBPSD UOP
6 FCC 411,412,413 205 KBPSD UOP
7 Delayed Coker 371 161 KBPSD Foster Wheeler
8 HMUs 521 & 522 3X181 TPD Linde
9 SRUs 451,452 & 453 3X675 TPD Pritchard
10 Platformer 231 & 232 89 KBPSD UOP
11 Aromatics (PX) 261,262 & 263 1.8 MMTPA UOP

12 Polypropylene 551 & 552 1050 KTA Dow

 Configuration - Capacity – Licensors (SEZ)
JMD
Sr. No. Process Unit Unit No. Capacity Technology
1 CDU/VDU/SGCU-1, 2 Z312 / 322 & Z311 / 321 2 * 290 KBPSD UOP/Bechtel
2 VGO HydroTreater-1, 2 Z361, Z364 2 * 110 KBPSD UOP
3 LCO Cracker Z354 50 KBPSD EMRE/KBR
4 DHDS 1 Z355 100 KBPSD EMRE/KBR
5 SCANfiner Z353 54 KBPSD EMRE/KBR
6 DHDS 2 Z358 120 KBPSD EMRE/KBR
7 PTU Z356 50 KBPSD EMRE/KBR
8 Coker Z371/Z372 160 KBPSD Foster Wheeler
9 FCCU Z411/412, 413/414 180 KBPSD UOP
10 PRU Z422 850 KTPA UOP
11 Alkylation Z429 83 KBPSD EMRE/KBR
12 Acid Regeneration Z430 1000 TPD MECS
13 Butamer Z435 42 KBPSD UOP
 Configuration - Capacity – Licensors (SEZ)
JMD
Sr. No. Process Unit Unit No. Capacity Technology
14 HNHT Z221 65 KBPSD UOP
15 Platformer/CCR Z231 85 KBPSD UOP
16 HMU 1- 5 Z521-5 5 * 181 TPD LINDE
17 Sat LPG Merox Z331 23 KBPSD UOP
18 Unsat LPG Merox Z415 75 KBPSD UOP
19 ATU-1-4 Z431-4 4 * 400 TPD UOP/Bechtel
20 SWSU-1-4 Z441-4 4 * 400 TPD UOP/Bechtel

21 SRU-1,2,3 Z451-3 3 * 675 TPD PRITCHARD

22 TGTU Z455 2025 TPD PRITCHARD
23 Polypropelene-E , F Z551 2 * 450 KTPA Dow - Unipol
 Block Flow Diagram - DTA
JMD

PX
SR Naphtha to Hydrogen
Aromatics OX /PX /Bz
HNUU/ Tatory+Pa- OX
Platformer rex Trains Light Reformate
Fuel Gas P
Sat LPG to ATU HA S/C , AHE R Bz
Fuel Gas O
Sat LPG Sat LPG D LPG
Merox Sat LPG U
Fuel Gas Kero C TAME
to ATU SKO /ATF T
Light Kero Merox S
SEZ Feed PCN
KHT P
R
Fuel Gas to ATU
Hydrotreated Diesel O Gasoline
CDU Diesel D
Kero & Gas HT LCO U
oil LSWR C
CRUDE Fuel Gas T ATF
Hydrotreated VGO B
FCC LPG Unsat LPG PRU
Propylene
PP
L
E
SKO
VGO Meroxes N
Ht Cut Naphtha

VDU VGO HT D
LCGO

LPG from Methanol Unsat LPG N

to HNUU

Coker G
Vacuum Residue

C5s TAME HSD

HCGO

Fuel Gas SHP / TAME B

to ATU L
Gasoline Unleaded Regular GasolineO LDO
C
Hy Cr Naphtha / C6 - 105 Merox K
SEZ HCN Fuel Gas CSO Clarified Slurry Oil (CSO) Reltrol

Lt Naphtha Fuel Gas/ Hydrogen Lt Naphtha from CBFS

Delayed to LNUU LPG/Naphtha Hydrogen Coker / FCC Hydrotreated
Coker Hy Naphtha Plant LNUU Lt Naphtha
to DHT TAME Raffinate
HCN
CNHT Rich Amine Sour Water PP
LPG to Unsat ATU, SRU & Fuel Gas
LPG Merox Stripped Water to ATU
Lean Amine SWS Sulphur
Platforme /DHTr Sulphur
Fuel Gas Coke
Coke
Coke
 Block Flow Diagram - SEZ JMD

Spent Caustic (MMTPA)

To Users PSA ETP
H2 Treater (DTA)
LPG Sat LPG Merox 2 PROPANE
DTA CNHT DTA Pt LPG C3
C3/C4 SPTR Caustic Trt
H2 DTA Sat LPG
HCN

DTA CNHT LPG C4 PCN

RECEIPT/ BLENDING / SALES – MARINE / MTF / RTF / RRTF

Btm Reformate
N.Splitter HNHT 2 PLATFORMER 2
NAPHTHA
L.NAP KER MEROX (DTA)
H2 DTA Feed
L. KEROSENE GASOLINE
HK H2 KHT (DTA)
CDU DHDS 1
DIESEL Btm
VDU PCN
Crude DHDS 2 ALKYLATE
H2 O/H C5
SGCU DTA Depentsr Pentane Treating unit

C5
LCGO A C3
3/4 JET
H2
GAS OIL VGOHT3/4 U.LPG U.Sat LPG C3= H2
PP 1/2
VGO FCCU 2 Merox 3 PRU 3
LCGO

LCNO

FO
A DTA C4= C4=
HCGO

NAPHTHA
HCN

DTA
LCO

LCO Alkylate DIESEL

DTA H2 BUTMR ALKYLATION
LPG

FCCU
VR Naphtha
COKER 2 LCO HC H2S/Disulphide
SAR
FO Fuel Oil
Sat Fuel
LPG SCANFINER
PET COKE

Gas H2 H2 ULSG
LCN

DTA
LCNO ULSD PP
HMU 4-8 To Users
H2
PTU ULSD
DTA LCN
Natural Gas H2 Recycle to Horticulture/ H2
CT / Fire Water
Fuel Comprn SULFUR
ETP 4-7 Fuel & Loss
Oil LEAN Amine
Sea WWSU 5-9
Process (3.11)
Brine
Diesel/LCO ATU 5-8 Units
Water SOUR WATER RICH Amine
to Sea CPP To Users
H2 PET COKE
Steam H2 SGU 2
TGTU SULFUR
Utility Power SRU 4-6
BFW LNUU(DTA) Products
WATER /N2/AIR To & From
AIR To Users Coke Handling System DTA
 Refining Processes
JMD

• Physical separation Processes

 Primary processes

 Separation by difference of Boiling Point

• Conversion Processes
 Left over heavy distillates ~ 35 to 55%

 Secondary processes

 Splitting long chain heavy components to lighter

Conversion Processes
JMD

• Thermal Cracking
 Visbreaker Unit

 Delayed Coker Unit

• Catalytic Cracking
 Fluidized Catalytic Cracking (FCC)

 Hydrocracking
Why FCC ?
JMD

• Advantages of FCC
 Cheapest available conversion process
 Offers great flexibility of operation – LPG / Gasoline &
Diesel mode of operations
 Produces large quantity of Petrochemical feed stocks
 Power & Steam generation from Waste Heat
Place of FCC in Refinery
JMD
LIGHT DISTILLATES

LIGHT DISTILLATES PRODUCTS

MIDDLE DISTILLATES MIDDLE DISTILLATES

CDU
HEAVY DISTILLATES VACUUM GAS OIL HEAVY
& DISTILLATE
VACUUM RESIDUE

VACUUM GAS OIL

VDU VACUUM RESIDUE

VACUUM RESIDUE

FCCU
LIGHT DISTILLATES LPG & GASOLINE

MIDDLE DISTILLATES LIGHT CYCLE OIL

HEAVY DISTILLATES CLARIFIED SLURRY OIL
HISTORY : FCC
JMD

• Thermal cracking: Heating in big vessels, 1930

• Activated alumina accidentally finds way to the thermal Vat
• Conversion increased suddenly & significantly
• Thus discovered by HOUDRY that Alumina was the catalyst for
the extra cracking in 1930
Growth of FCC Technology
JMD
Gasoline “S”
Ni Passivation(Bi) reduction
additive
Octane Additive
Technology Development Commercial
VANADIUM Passivation (Sn) Octane cat
Sox Additives
Ni Passivation(Sb) Pt-Based Promoters

Riser Cracking
USY Catalysts
Zeolite Catalysts

Y Zeolite
TCC

First Commercial FCC

First Fixed Bed Cat. Cracker

1940 1950 1960 1970 1980 1990 2000
Year
Configurations of Rx / Rg
JMD
Configurations of Rx / Rg
JMD
 Position of FCC in Jamnagar Complex
JMD

PX
SR Naphtha to Hydrogen
Aromatics OX /PX /Bz
HNUU/ Tatory+Pa- OX
Platformer rex Trains Light Reformate
Fuel Gas P
Sat LPG to ATU HA S/C , AHE R Bz
Fuel Gas O
Sat LPG Sat LPG D LPG
Merox Sat LPG U
Fuel Gas C TAME
to ATU Kero T
Light Kero SKO /ATF
Merox S
PCN
P
Fuel Gas to ATU R
Hydrotreated Diesel O Gasoline
CDU Diesel D
Kero & Gas HT LCO U
oil LSWR C
CRUDE Fuel Gas T ATF
Hydrotreated VGO B
FCC LPG Unsat LPG PRU
Propylene
PP
L
E
SKO
Ht Cut Naphtha

VGO Meroxes N
D
VDU VGO HT
LCGO

to HNUU

LPG from Methanol Unsat LPG N

Vacuum Residue

Coker G
C5s HSD
HCGO

TAME
Fuel Gas
to ATU
SHP / TAME B
L
Unleaded Regular Gasoline O LDO
Gasoline C
Hy Cr Naphtha / C6 - 105 Merox K
Reltrol
Fuel Gas CSO Clarified Slurry Oil (CSO)

Lt Naphtha Fuel Gas/ Lt Naphtha from CBFS

Delayed to LNUU Hydrogen Hydrogen Coker / FCC
LPG/Naphtha Hydrotreated
Coker Hy Naphtha Plant Lt Naphtha
to DHT TAME Raffinate
LNUU

Rich Amine Sour Water PP

LPG to Unsat ATU, SRU & Fuel Gas
LPG Merox Stripped Water to ATU
Lean Amine SWS Sulphur
Sulphur
Fuel Gas Coke
Coke
Coke
FCC Complex Overview
JMD

• Heart of Jamnagar Refinery Complex

• World largest FCCU – 205 KBPSD (both

DTA & SEZ)

• 3 Propylene Recovery Units (PRU) –

6500 TPD of Propylene production

• Selective Hydrogenation Unit (SHP) –

900 MT of TAME production

• Process Licensor – UOP

• FCC-1 commissioned in 1999, revamped

in 2005 & 2011

• FCC-2 commissioned in 2009

FCC Complex Plot Plan
JMD
FCC Complex – Feed Stocks & Products
JMD

Unit Feed Products

FCCU  Hydrotreated VGO from VGO  Fuel Gas
Hydrotreaters & Tankage  LPG
 Imported Low Sulphur Waxy  SHP unit feed (C5)
Residue (LSWR)
 Heart Cut Naphtha
 Gasoline
 Light Cycle Oil (LCO)
 Clarified Slurry Oil (CSO)
PRU  Treated LPG from Merox  Propylene
units  Propane
 C4s to Alky / LPG blending
SHP/TAME  C5 feed from FCCU  TAME
 Raffinate
FCC Design
JMD

Capacity 205 KPBSD

Feed Rate 1230 T/hr
Product Yields ( % )
Fuel Gas 5.5
LPG ( Propylene) 30 ( 9.8 %)
Gasoline 35
LCO 13
CSO 8
Coke 5.5
FCC overview
JMD

FCC Complex Overview

Fuel Gas
LPG
Unsat SHP Feed
Flue gas Gas LMOG
Conc
Hr Cut
Section
Main Naphtha
Catalyst Column HMOG
Reactor HCN
Regenerator
SHP Merox
LCO
CSO TAME
Air Feed
TAME
PRT Stack PRU
LPG
Propylene
Sections of FCCU
JMD

• Unit – 411

– Reactor / Riser/Regenerator/Catalyst Hoppers

• Unit – 412

– Power Recovery Trains/TSS / FSS / Flue Gas Coolers

• Unit – 413

– Main Fractionator / Side Stripper

• Unit – 414

– Wet Gas Compressor/Primary Absorber / Stripper / Debutaniser /

Depentaniser / Naphtha Splitter / De-isoheaxnizer
Reactor / Regenerator Section
JMD
 PRT Section
JMD

Third Stage Orifice Chamber Diverter

Flue Gas Cooler
C1
Separator Valve

A1 Stack

Expander
Critical Flow
Fourth Stage
Nozzle
Flue Gas Separator

Recovered Cat
Hopper
Regenerator Goggle valves

A2 Third Stage Orifice Chamber Diverter

Flue Gas Cooler
C2 B
Separator Valve

Stack

Expander
Critical Flow
Fourth Stage Nozzle
Separator
 Power Recovery Train
JMD

To FGC Air
HP Steam

M/G
Flue Gas -9.0 MW
S.T. +2.5 MW
from Regen Exp MAB G.B.
29 MW 31 MW 14 MW

LP Steam
Air to Regenerator
 MAIN FRACTIONATOR
JMD

Main Column Main Column

Main Condenser Trim Condenser Main Column
Column Receiver

Refl ux l i ne Main Column

1
Reflux drum WGC I
stage suction
Col d VG O
feed 10 valve
Hot VG O 1 WGC I
feed stage suction
26 HN
Imp. F uel 6 strippervalve
oi l
1
Raw oi l feed
HN product pump
surge drum Comp. suction
6 LCO drum pumps
Raw oi l feed stripper
pumps sucti on
LCO product pumps
42
To HCO circ. pumps
Reactor Vap line To MCB circ. pumps
blind in position suction
Un saturate Gas Concentration Unit
JMD
Amine H.P.F.Gas
FROM WGC C51
Primary Absorber Absorber Compressor- C02
TO WGC C51 L.G.KOD Fuel gas
to RFG
1 L.G.Water Lean System
HP receiver 10 Wash Column Amine 1
Maincolumn V-07

O/H Vapoure 414-A02 To LCO

1 V
6 16
Maincolumn O/H 414 Fuel gas
C103 to GT
To Interstage
414
40 Liquid 35
receiver
414-A02
C05 T.G.KOD
To Sour
Water
Stripper
P04A/B Rich
LS WGC - C01 414 -V04 Depentaniz Sponge Absorber Amine
er 62 C
C 101 1.56 bar 471-A03
A 107
Stripper 1 Deisohexanizer 1

1 471-V03
47
S 107 V102
LMG
26
C5 to SHP 100 C CW
59
MS
Unit 1.7 bar
39
LNUU
36 S 108A,B 80
LS
S 120,121 61

LCO C5 to
SHP
To
S 09 A,B LS Unit LNUU/
134 C
Supply 1.84 bar LMG
A 05 S 103 A-C
177 C
H-Cut
1
3.0 bar Nap to
1 414-S17 104 C HNUU
1.21 bar
A 06
21
414-V114 22
V10
Debutanizer 26
414- S 124 1 414-V10
C09 LP 50 15
BFW
27 To
41
S 14A- L 1.LNUU
C,114 S 13 Sat HP
C 2.Mogas
O 3. Riser
HCO

Steam
LPG to 28

S18 A,B
HCO

LCO
1. Merox 41
2. Off spec H
Sphere
195 C
1.63 bar C To
To O
1.HMOG
Nap vs BFW Cooler Naphtha Splitter 2 2. Naptha Cooler
Naphtha Splitter 1
Feed Characteristics
JMD

• API
• Change may be due to boiling range and/or crude type
• Higher API
– Feed cracks more readily for same Rx temp, higher conversion
– At constant conversion, higher gasoline yield with lower
octane
– Products will be less olefinic
• UOP ‘K’
• UOP ‘K’ = (CABP)1/3 / SG
• Higher UOP’K’
– More paraffinic feed/ Easier to crack
Feed Characteristics
JMD

• Carbon residue
• Indirect measure of coke producing tendency
• Dependent of crude source (for VGO) or feed mix
• Increase in carbon residue
– Increases regenerator temperature (for same crude source)
– Reduces cat / oil ratio
– Usually coupled with higher metal levels
• Impurities
• Sulfur
• Nitrogen
• Metals (Nickel, Vanadium, Sodium)
FCC CATALYSTS & ADDITIVES
JMD

 Fine Porous Powder

 Oxides of Silica & Alumina

 Acid sites associated with alumina

 Other elements in small amounts

 Acts like fluid when aerated (Fluidised)

 Tailor made for specific requirement

PROCESS VARIABLES
JMD

• Reactor related
 Temperature
 Cat / Oil ratio
 Reaction time, Pressure
• Regenerator related
 CRC, Air rate and distribution
 Temperature, Pressure, Time
 Regeneration Design, Mode of regeneration
• Feed Stock
 Charge rate and recycle
 Characteristic
 Preheat temperature
• Catalyst type and condition
Process Variable & its Effect
JMD

GENERAL YIELD DISTRIBUTION

LPG
CONVERSION

LPG
SEVERITY
SEVERITY
GASOLINE

LCO

SEVERITY SEVERITY
PRU overview
JMD

S-Treaters
C2- to FCC
Reflux

Heat Pump Propylene

Compressor

LPG C3-/C3=
feed C3/C4 DeC2 Column
Column Column

Reboiler

C4-LPG Propane
SHP overview
JMD
( Fresh+ Recycle)
C5 feed
Hydrogen Off Gas
to FG

SHP
Stripper
Rx

Partial Recycle to feed

C5 ( Essentially mono-olefins)
TAME Overview
JMD

C5 feed ( Water washed, Nitrile free) Methanol

Raffinate recycle to
Methanol feed
( Fresh+ Recycle)

Raffinate
TAME Pentene Methonal
Wash
Rx Column Col
Column

TAME
Cold Clean
Condensate
FCC Complex overview
PRU / SHP-TAME Salient Features
JMD

 Propylene production capacity of 6500 MTPD

 Heat pump compressor usage instead of conventional condenser - Energy

efficient

 C3 splitter is one of the world tallest distillation tower

 Enhanced Multi down comer trays in C3 Splitter for enhanced separation

 Hi-flux tubing in C3 splitter Reboiler which reduces the size of the exchanger by
5 - 10 times.

 TAME - Octane booster for gasoline (5-10% increase in RON)

FCC Complex overview
Salient differences between DTA & SEZ FCCs
JMD

S.No Particular DTA FCC Complex SEZ FCC Complex

1 Reactor • 15 Feed Nozzles • 18 Feed Nozzles

• No Rx Cat • Rx Cat
• Baffled Stripper • Packed Stripper
2 Regenerator • No Elephant trunk in • Elephant trunk in
combustor riser combustor riser
3 Expander • E-148 Frame Size • E 156 Frame Size
• Single inlet valve • Block & Bleed valves
4 Gas Con • 2 Naphtha Splitters • Single Naphtha Splitter
Section • Chiller for C3= recovery • LNS for C3= recovery
• RFG Compressor • No RFG Compressor

5 PRU / SHP / • 2 PRUs (550 m3/hr feed) • Single PRU (600 m3/h)
TAME • SHP / TAME unit • No SHP / TAME Unit
FCC Complex overview
JMD

THANKS

Please proceed for the post test…………….

 THANKS

Please proceed for the

post test