FCC

Details of four FCC APC training sessions follow (Four sessions if attendees have not taken wide cut and narrow cut fractionation courses).

1. FCC operation and economics (100 minutes):

• Overview – the theory of FCC reaction.
• Feed and product: destinations, specifications and unit economics.
• Equipment configuration: reactor, regenerator, compressor blower, main fractionator, gas plant, etc.
• Scope: Full burn, part burn, vacuum gasoil and atmospheric resid feed.
• Severity, conversion, crackability.
• Key handles: Reactor temperature, fresh feed temperature, reactor pressure, reactor – regenerator pressure difference.
• Fractionator handles: Top temperature, draws, cooling circuits, stripping steam.
• Gas plant handles: reboilers, reflux flows, absorber lean-oil, etc.
• APC requirements.

2. Reactor/regenerator inferential modeling (90 minutes).

• Catalyst circulation model.
• Severity inference based on riser conditions.
• Regenerator coke burn model.
• Conversion measurement and/or inference.
• Feed properties: crackability and coke make tendency.

3. Fractionator and gas plant inferential modeling (100 minutes):

Please note: If attendees have not taken the wide cut and narrow cut training there would be two sessions of 100 minutes each.

• Main fractionator inferences – see wide cut fractionation.
  • Product cutpoints, flashpoints, internal reflux at key points.
• Gas plant inferences – see narrow cut fractionation.
  • Product purities, loading of key trays.

4. FCC APC (100 minutes):

• Unit constraints and APC structure: CV’s, DV’s and MV’s In the reactor, fractionator and gas plant sections.
• Feedstock switching contro.
• Throughput (or severity) maximization issues, cover the many constraints: Catalyst flow limit, regenerator after-burn at high C/O ratio, compressor limit, blower limits, cyclone velocity, fractionator or gas plant limits.
• Balancing to meet more than one constraint at a time