Yes / The Riser of a Fluid Catalytic Cracking (FCC) unit cracks gas oil to make fuels such as gasoline and diesel. However, changes in quality, nature of crude oil blends feedstocks, environmental changes and the desire to obtain higher profitability, lead to many alternative operating conditions of the FCC riser. The production objective of the riser is usually the maximization of gasoline and diesel. Here, an optimisation framework is developed in gPROMS to maximise the gasoline in the riser of an industrial FCC unit (reported in the literature) while optimising mass flowrates of catalyst and gas oil. A detailed mathematical model of the process developed is incorporated in the optimisation framework. It was found that, concurrent use of the optimal values of mass flowrates of catalyst (310.8 kg/s) and gas oil (44.8 kg/s) gives the lowest yield of gases, but when these optimum mass flowrates are used one at time, they produced the same and better yield of gasoline (0.554 kg lump/ kg feed). / Petroleum Technology Development Fund, Nigeria, financially sponsored the study.

Yes / The FCC riser cracks gas oil into useful fuels such as gasoline, diesel and some lighter products such as ethylene and propylene, which are major building blocks for the polyethylene and polypropylene production. The production objective of the riser is usually the maximization of gasoline and diesel, but it can also be to maximize propylene. The optimization and parameter estimation of a six-lumped catalytic cracking reaction of gas oil in FCC is carried out to maximize the yield of propylene using an optimisation framework developed in gPROMS software 5.0 by optimizing mass flow rates and temperatures of catalyst and gas oil. The optimal values of 290.8 kg/s mass flow rate of catalyst and 53.4 kg/s mass flow rate of gas oil were obtained as propylene yield is maximized to give 8.95 wt%. When compared with the base case simulation value of 4.59 wt% propylene yield, the maximized propylene yield is increased by 95%.

Yes / A detailed steady state FCC riser process model is simulated for the first time with different compressibility (Z) factor correlations using gPROMS software. A 4-lump kinetic model is used where gas oil cracks to form gasoline, coke and gases. The usual practice has been the assumption that the FCC riser gas phase is an ideal gas at every point under any condition (varying C/O ratio, riser diameter, operating temperature and pressure, etc.). This work found that the Z factor varies at every point across the riser height depending on riser operating pressure and temperature, diameter and C/O ratio. It also shows that the magnitude of deviation of a gas phase from ideal gas behaviour can be measured over the riser height. The Z factor correlation of Heidaryan et al. (2010a) is found to be suitable for predicting the Z factor distribution in the riser. / Petroleum Technology Development Fund, Nigeria

Yes / In this work a simulation of detailed steady state model of an industrial fluid catalytic cracking (FCC) unit with a newly proposed six-lumped kinetic model which cracks gas oil into diesel, gasoline, liquefied petroleum gas (LPG), dry gas and coke. Frequency factors, activation energies and heats of reaction for the catalytic cracking kinetics and a number of model parameters were estimated using a model based parameter estimation technique along with data from an industrial FCC unit in Sudan. The estimated parameters were used to predict the major riser fractions; diesel as 0.1842 kg-lump/kg-feed with a 0.81% error while gasoline as 0.4863 kg-lump/kg-feed with a 2.71% error compared with the plant data. Thus, with good confidence, the developed kinetic model is able to simulate any type of FCC riser with six-lump model as catalyst-to-oil (C/O) ratios were varied and the results predicted the typical riser profiles.

The Fluidized Catalytic Cracking (FCC) is known for its ability to convert refinery wastes into useful fuels such as gasoline, diesel and some lighter products such as ethylene and propylene, which are major building blocks for the polyethylene and polypropylene production. It is the most important unit of the refinery. However, changes in quality, nature of crude oil blends feedstock, environmental changes and the desire to obtain higher profitability, lead to many alternative operating conditions of the FCC riser. There are two major reactors in the FCC unit: the riser and the regenerator. The production objective of the riser is the maximisation of gasoline and diesel, but it can also be used to maximise products like propylene, butylene etc. For the regenerator, it is for regeneration of spent or deactivated catalyst. To realise these objectives, mathematical models of the riser, disengage-stripping section, cyclones and regenerator were adopted from the literature and modified, and then used on the gPROMS model builder platform to make a virtual form of the FCC unit. A new parameter estimation technique was developed in this research and used to estimate new kinetic parameters for a new six lumps kinetic model based on an industrial unit. Research outputs have resulted in the following major products’ yields: gasoline (plant; 47.31 wt% and simulation; 48.63 wt%) and diesel (plant; 18.57 wt% and simulation; 18.42 wt%) and this readily validates the new estimation methodology as well as the kinetic parameters estimated. The same methodology was used to estimate kinetic parameters for a new kinetic reaction scheme that considered propylene as a single lump. The yield of propylene was found to be 4.59 wt%, which is consistent with published data. For the first time, a Z-factor correlation analysis was used in the riser simulation to improve the hydrodynamics. It was found that different Z factor correlations predicted different riser operating pressures (90 – 279 kPa) and temperatures as well as the riser products. The Z factor correlation of Heidaryan et al. (2010a) was found to represent the condition of the riser, and depending on the catalyst-to-oil ratio, this ranges from 1.06 at the inlet of the riser to 0.92 at the exit. Optimisation was carried out to maximise gasoline, propylene in the riser and minimise CO2 in the regenerator. An increase of 4.51% gasoline, 8.93 wt.% increase in propylene as a single lump and 5.24 % reduction of carbon dioxide emission were achieved. Finally, varying the riser diameter was found to have very little effect on the yields of the riser products.