(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
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