US3629097A - Control system for fluid catalytic cracking process - Google Patents

Control system for fluid catalytic cracking process Download PDF

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Publication number
US3629097A
US3629097A US1002A US3629097DA US3629097A US 3629097 A US3629097 A US 3629097A US 1002 A US1002 A US 1002A US 3629097D A US3629097D A US 3629097DA US 3629097 A US3629097 A US 3629097A
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United States
Prior art keywords
temperature
reactor
regenerator
conduit
lower portion
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Expired - Lifetime
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US1002A
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English (en)
Inventor
John H Smith
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ConocoPhillips Co
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Continental Oil Co
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Publication date
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    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G11/00—Catalytic cracking, in the absence of hydrogen, of hydrocarbon oils
    • C10G11/14—Catalytic cracking, in the absence of hydrogen, of hydrocarbon oils with preheated moving solid catalysts
    • C10G11/18—Catalytic cracking, in the absence of hydrogen, of hydrocarbon oils with preheated moving solid catalysts according to the "fluidised-bed" technique
    • C10G11/187—Controlling or regulating
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S208/00—Mineral oils: processes and products
    • Y10S208/01—Automatic control

Definitions

  • Coke deposition rate in the reactor of a fluid cat cracker is controlled by varying the severity and conversion level in the reactor, while maintaining maximum air rate to the regenerator.
  • the temperature at the outlet of the regenerator which is an indication of afterburning and amount of coke buildup, is used to control reactor temperature and catalystto-oil ratio in the reactor (by resetting the reactor temperature recorder control, which in turn controls the flow of hot regenerated catalyst from the regenerator to the reactor), thus controlling coke deposition to make it commensurate with air supply by controlling the severity and conversion level in the reactor.
  • the temperature in the regenerator catalyst bed is held constant by varying the recycle feed rate to the reactor in response to variations in such temperature.
  • This invention is an improved control system for a conventionalfluid catalytic cracker.
  • The-improvement consists of a method and apparatus for maximizing the coke burning rate in the regenerator by operating the air compressor at maximum capacity and controlling the coke deposition rate in the reactor by varying the reaction severity in response to variations in air supply from the compressor. More specifically, the improvement consists of method and apparatus for controlling the temperature in the regenerator catalyst bed by varying the recycle feed rate to the reactor.
  • FIGURE is a simplified flow diagram of a fluid catalytic cracking unit embodying my invention.
  • compressor 1 runs at maximum speed on governor control, delivering all the air it can compress into regenerator 2 in which the pressure is held constant (preferably at about 10-30 p.s.i.g.) by a pressure recorder controller (PRC) 3a operating a back pressure valve in the flue gas exit line 3.
  • PRC pressure recorder controller
  • FRC flow rate control
  • TRC temperature recorder controller
  • the temperature within the reactor is controlled to maintain a reactor temperature preferably within the range of about 890-960 F., by a tem- LII perature recorder controller alarm (TRCA) 15 which regulates the position of the slide valve 13 in the regenerated catalyst standpipe 12.
  • TRCA tem- LII perature recorder controller alarm
  • the amount of afterburning which occurs in regenerator 2 is controlled by controlling its flue gas exit temperature with a temperature recorder controller (TRC) 16 which resets the control point on TRCA 15 which directly controls the reactor temperature.
  • TRC temperature recorder controller
  • FRC flow recorder control
  • the position of slide valve 21 is regulated by a level recorder controller 22 to maintain a constant head of catalyst above the base of stripper.
  • the catalyst level may extend up into the reactor if desired.
  • the heat input to a catalytic cracker must equal the heat output; otherwise system temperatures might rise or fall to damaging levels.
  • the sum total heat input via combustion within the regenerator 2 must equal the sum of the radiation losses, the sensible heat surrendered to the flue gas leaving the regenerator, and the sensible, latent, and reaction heats surrendered to the product vapors from the reactor 14.
  • regenerator TRC 11 would react by decreasing the control setting of FRC 5a. This in turn would decrease the recycle feed rate (line 5) to riser 7, thereby reducing the rate of heat withdrawal from the system and thus bringing heat input and output back into balance and returning the regenerator temperature to its control point. It is readily apparent that by reacting in opposite fashion, the control system just described will limit the degree to which the regenerator temperature can climb above the control point.
  • a typical unit operates at or near the following conditions:
  • the control temperature setting on the TRC 16 must be somewhat higher than that on TRC 11 to insure controlled afterburning. This difference should be at least 5 F. to ensure reasonable controllability but should not be so high as to be wasteful of air that might be better used for burning additional coke which would result from raising conversion. In some instances it might be desirable to operate with a flue gas exit temperature 50 F. or more above the regenerator dense phase temperature to maintain a high mean oxygen concentration in the gases rising through the dense phase to reduce the residual coke content on regenerated catalyst to a lower level than would otherwise be achieved. For this control scheme to function properly, it is obviously necessary that the controlled temperature level in the regenerator dense phase exceed the ignition temperature of carbon monoxide. The preferred temperature is about l,200 to 1,225 F.
  • the temperature of the flue gas exiting from the top of regenerator should tend to fall below the control point, it would signify that there was a reduction in afterburning because of a drop in oxygen content of the flue gases rising from the dense phase. This in turn would signify that the means concentration of coke on catalyst in the regenerator was rising which would means that coke was being deposited at a faster rate than it was being burned.
  • the flue gas TRC 16 would immediately lower the control setting on the TRCA which would, in turn, reposition (reduce the opening of) the slide valve 13 in the regenerated catalyst standpipe 12.
  • the system may be simplified further by substituting potentiometers or other temperature sensing means for TRC l6 and allowing the operator to manually reset TRCA 15.
  • the reactor temperature control 15 includes highand lowtemperature alarms which alert the operator if the temperature reaches either alarm setting. The operator then takes appropriate action to bring the reactor temperature back within the prescribed range. For example, if the high-temperature alarm should sound, he would take some action to increase the severity of some reaction control variable other than temperature. This might be an increase in reactor catalyst level, catalyst activity, or slurry recycle rate, or a reduction in dilution steam rate to the riser or regenerator dense phase temperature. If the low temperature alarm should sound, the operator would take some action opposite to those just described. Alternatively, the reactor temperature control might be equipped with one or more reset mechanisms to automatically effect one or more of the changes indicated.
  • control system could be made more complex as indicated in the last paragraph, I prefer the simple version as described and depicted in the drawing, relying upon the operator to take appropriate action to keep the reactor temperature within the alarm settings.
  • This plan of control will improve the results obtainable with any feedstock otherwise suitable for catalytic cracking and will be especially beneficial for any feedstock that varies in quality during operations.
  • Suitable catalysts are conventional fluid catalytic cracking catalysts, which are well known in the art.
  • a reactor having a first conduit attached to the upper portion thereof, a stripper attached to lower portion thereof, and a temperature recorder controller alarm attached to said reactor;
  • regenerator having attached to the upper portion thereof a second conduit and means to control the pressure in the regenerator, and having attached to the lower portion thereof a third conduit, equipped with a valve, said third conduit extending up into the lower portion of the regenerator, and a fourth conduit connected to the lower portion of the regenerator, said fourth conduit having an air compressor connected thereto;
  • thermosensing means connected to the upper portion of the regenerator, said temperature-sensing means being operatively connected to said means (0);
  • Temperature-sensing means connected to the lower portion of the regenerator, said temperature-sensing means being operatively connected to said flow rate control means in said seventh conduit.
  • thermo sensing means comprises temperature control means for changing the control setting of said flow rate control means in response to temperature variations in the lower portion of the regenerator.

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  • Chemical & Material Sciences (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)
US1002A 1970-01-06 1970-01-06 Control system for fluid catalytic cracking process Expired - Lifetime US3629097A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US100270A 1970-01-06 1970-01-06

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US3629097A true US3629097A (en) 1971-12-21

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US (1) US3629097A (fr)
BE (1) BE760975R (fr)
CA (1) CA923445A (fr)
DE (1) DE2061191A1 (fr)
GB (1) GB1319519A (fr)
IT (1) IT947046B (fr)
NL (1) NL7015255A (fr)
ZA (1) ZA707879B (fr)

Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4006075A (en) * 1975-01-06 1977-02-01 Exxon Research And Engineering Company Method of regenerating a cracking catalyst with substantially complete combustion of carbon monoxide
US4072600A (en) * 1974-02-08 1978-02-07 Mobil Oil Corporation Catalytic cracking process
US4088568A (en) * 1976-01-15 1978-05-09 Mobil Oil Corporation Catalytic cracking of hydrocarbons
US4092722A (en) * 1976-10-18 1978-05-30 Phillips Petroleum Company Fluid catalytic cracking with automatic temperature control
US4152292A (en) * 1972-05-30 1979-05-01 Universal Oil Products Company Method of initiating essentially complete oxidation of co to co2 in a spent-catalyst regeneration zone
US4159239A (en) * 1973-09-20 1979-06-26 Mobil Oil Corporation Catalytic cracking process
US4174272A (en) * 1973-09-20 1979-11-13 Mobil Oil Corporation Catalytic cracking of hydrocarbons
US4311580A (en) * 1979-11-01 1982-01-19 Engelhard Minerals & Chemicals Corporation Selective vaporization process and dynamic control thereof
US5389236A (en) * 1993-04-21 1995-02-14 Bartholic; David B. Method and apparatus for controlling introduction of catalysts into FCC units
US20080128325A1 (en) * 2006-11-07 2008-06-05 Saudi Arabian Oil Company Advanced control of severe fluid catalytic cracking process for maximizing propylene production from petroleum feedstock
US20090095657A1 (en) * 2006-11-07 2009-04-16 Saudi Arabian Oil Company Automation and Control of Energy Efficient Fluid Catalytic Cracking Processes for Maximizing Value Added Products
US20100230324A1 (en) * 2006-11-07 2010-09-16 Saudi Arabian Oil Company Control of Fluid Catalytic Cracking Process for Minimizing Additive Usage in the Desulfurization of Petroleum Feedstocks
US11118117B2 (en) * 2019-05-23 2021-09-14 Kellogg Brown & Root Llc Regulatory controller for usage in a catalytic olefins

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3263622D1 (en) * 1981-02-13 1985-06-13 Residual Oil Proc Res Ass Process for simultaneously cracking heavy hydrocarbons into light oils and producing hydrogen, and light oils and hydrogen when so produced

Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2409751A (en) * 1943-12-22 1946-10-22 Universal Oil Prod Co Catalytic conversion of hydrocarbons
US3175968A (en) * 1961-06-23 1965-03-30 Phillips Petroleum Co Automatic control and optimization of a fluidized catalytic cracker
US3206393A (en) * 1964-11-24 1965-09-14 Universal Oil Prod Co Fluid catalytic cracking of hydrocarbons
US3213014A (en) * 1962-06-14 1965-10-19 Phillips Petroleum Co Computer control of hydrocarbon conversion
US3238121A (en) * 1963-03-12 1966-03-01 Socony Mohil Oil Company Inc Hydrocarbon conversion process and apparatus useful therefor
US3238122A (en) * 1964-01-17 1966-03-01 Socony Mobil Oil Co Inc Hydrocarbon conversion process and apparatus useful therefor
US3261777A (en) * 1962-08-14 1966-07-19 Chevron Res Controlling coke laydown in a catalytic conversion process
US3316170A (en) * 1966-01-03 1967-04-25 Phillips Petroleum Co Control system for maximum heat utilization in process for fluid catalytic decomposition conversion of hydrocarbons
US3410793A (en) * 1966-06-27 1968-11-12 Texaco Inc Method and apparatus for controlling the regeneration of contaminated solids in a fluidized system

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2409751A (en) * 1943-12-22 1946-10-22 Universal Oil Prod Co Catalytic conversion of hydrocarbons
US3175968A (en) * 1961-06-23 1965-03-30 Phillips Petroleum Co Automatic control and optimization of a fluidized catalytic cracker
US3213014A (en) * 1962-06-14 1965-10-19 Phillips Petroleum Co Computer control of hydrocarbon conversion
US3261777A (en) * 1962-08-14 1966-07-19 Chevron Res Controlling coke laydown in a catalytic conversion process
US3238121A (en) * 1963-03-12 1966-03-01 Socony Mohil Oil Company Inc Hydrocarbon conversion process and apparatus useful therefor
US3238122A (en) * 1964-01-17 1966-03-01 Socony Mobil Oil Co Inc Hydrocarbon conversion process and apparatus useful therefor
US3206393A (en) * 1964-11-24 1965-09-14 Universal Oil Prod Co Fluid catalytic cracking of hydrocarbons
US3316170A (en) * 1966-01-03 1967-04-25 Phillips Petroleum Co Control system for maximum heat utilization in process for fluid catalytic decomposition conversion of hydrocarbons
US3410793A (en) * 1966-06-27 1968-11-12 Texaco Inc Method and apparatus for controlling the regeneration of contaminated solids in a fluidized system

Cited By (17)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4152292A (en) * 1972-05-30 1979-05-01 Universal Oil Products Company Method of initiating essentially complete oxidation of co to co2 in a spent-catalyst regeneration zone
US4159239A (en) * 1973-09-20 1979-06-26 Mobil Oil Corporation Catalytic cracking process
US4174272A (en) * 1973-09-20 1979-11-13 Mobil Oil Corporation Catalytic cracking of hydrocarbons
US4072600A (en) * 1974-02-08 1978-02-07 Mobil Oil Corporation Catalytic cracking process
US4006075A (en) * 1975-01-06 1977-02-01 Exxon Research And Engineering Company Method of regenerating a cracking catalyst with substantially complete combustion of carbon monoxide
US4098680A (en) * 1975-01-06 1978-07-04 Exxon Research & Engineering Co. Method of regenerating a cracking catalyst
US4088568A (en) * 1976-01-15 1978-05-09 Mobil Oil Corporation Catalytic cracking of hydrocarbons
US4092722A (en) * 1976-10-18 1978-05-30 Phillips Petroleum Company Fluid catalytic cracking with automatic temperature control
US4311580A (en) * 1979-11-01 1982-01-19 Engelhard Minerals & Chemicals Corporation Selective vaporization process and dynamic control thereof
US5389236A (en) * 1993-04-21 1995-02-14 Bartholic; David B. Method and apparatus for controlling introduction of catalysts into FCC units
US20080128325A1 (en) * 2006-11-07 2008-06-05 Saudi Arabian Oil Company Advanced control of severe fluid catalytic cracking process for maximizing propylene production from petroleum feedstock
US20090095657A1 (en) * 2006-11-07 2009-04-16 Saudi Arabian Oil Company Automation and Control of Energy Efficient Fluid Catalytic Cracking Processes for Maximizing Value Added Products
US20100230324A1 (en) * 2006-11-07 2010-09-16 Saudi Arabian Oil Company Control of Fluid Catalytic Cracking Process for Minimizing Additive Usage in the Desulfurization of Petroleum Feedstocks
US9701914B2 (en) 2006-11-07 2017-07-11 Saudi Arabian Oil Company Advanced control of severe fluid catalytic cracking process for maximizing propylene production from petroleum feedstock
US9764314B2 (en) 2006-11-07 2017-09-19 Saudi Arabian Oil Company Control of fluid catalytic cracking process for minimizing additive usage in the desulfurization of petroleum feedstocks
US11505752B2 (en) * 2018-05-23 2022-11-22 Kellogg Brown & Root Llc Regulatory controller for usage in a catalytic olefins unit
US11118117B2 (en) * 2019-05-23 2021-09-14 Kellogg Brown & Root Llc Regulatory controller for usage in a catalytic olefins

Also Published As

Publication number Publication date
GB1319519A (en) 1973-06-06
IT947046B (it) 1973-05-21
CA923445A (en) 1973-03-27
DE2061191A1 (de) 1971-07-22
NL7015255A (fr) 1971-07-08
BE760975R (fr) 1971-05-27
ZA707879B (en) 1971-08-25

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Owner name: UOP, DES PLAINES, IL, A NY GENERAL PARTNERSHIP

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST.;ASSIGNOR:KATALISTIKS INTERNATIONAL, INC., A CORP. OF MD;REEL/FRAME:005006/0782

Effective date: 19880916

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Owner name: UOP, A GENERAL PARTNERSHIP OF NY, ILLINOIS

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST.;ASSIGNOR:UOP INC.;REEL/FRAME:005077/0005

Effective date: 19880822