I.FLUID CATALYTIC CRACKING: www.wissenschaftler-avh.in
B.CATALYST/ADDITIVES(Contd.)
Q.37 What tools are being used to monitor the FCC performance? What are the key performance indicators (KPIs) and expectations?
A-37
There are many tools that are available to monitor FCC unit performance. Most FCC operators monitor in process, or “as produced”yields and operating conditions, and additionally they complete unit mass balances at routine intervals (often weekly or more frequently).
Of primary importance is the net product value produced by running the FCC. This is most often examined using mass balanced data from the unit, in conjunction with refinery specific product and feed values (pricing). In many refineries, FCC profitability is driven by overall volume gain, so this is an important KPI.
Unit reliability is also a very important profitability parameter, and (along with a strong routine maintenance program), many refiners monitor in process operating parameters to ensure that limits are not being exceeded. Some of these parameters are directly measured in the unit, and some are calculated using in-process or mass balanced data.
Measured parameters include unit temperatures (at various points in the unit, including reactor outlet, regenerator bed, reactor and regenerator dilute phases, and others), unit pressures (reactor & regenerator), wet gas compressor suction and power, regenerator emissions, and slide valve / standpipe differential pressures.
Calculated parameters, which are important to monitor, include yield selectivities (yields / conversion), coke make, superficial velocities (especially in cyclones), and catalyst circulation (or cat-to-oil ratio).The recommended ranges for all of these parameters are specific to the FCC unit’s configuration, feed and catalyst type, and operating strategy.
Equilibrium catalyst analysis reports can be a critical tool to monitor FCC unit performance, and to troubleshoot the various problems that can arise in typical FCC unit operation. They are most effectively used when they are incorporated into routine operating reviews with the catalyst supplier. During the reviews, recommendations are often made to adjust operating strategies or fresh catalyst formulation to address future operations or issues that are expected/anticipated for the refinery. These routine reviews are a critical component of the successful operation of the FCC.
The catalyst KPI’s include cracking data (ACE or MAT), physical properties of the catalyst, and chemical analysis of the catalyst. As with yield and operating KPI’s the expectation for these KPI’s varies greatly depending on the feed processed, unit design, catalyst type,and operating strategy of the refinery.In addition, equilibrium catalyst data can be used to benchmark unit performance against similar units, feed types, catalyst types, or a number of other variables. Advanced analytical tools and methods have been developed by catalyst suppliers to understand how age distribution, cyclone performance, contaminant metals, and other variables may impact the performance of the FCC catalyst.
B.CATALYST/ADDITIVES(Contd.)
Q.37 What tools are being used to monitor the FCC performance? What are the key performance indicators (KPIs) and expectations?
A-37
There are many tools that are available to monitor FCC unit performance. Most FCC operators monitor in process, or “as produced”yields and operating conditions, and additionally they complete unit mass balances at routine intervals (often weekly or more frequently).
Of primary importance is the net product value produced by running the FCC. This is most often examined using mass balanced data from the unit, in conjunction with refinery specific product and feed values (pricing). In many refineries, FCC profitability is driven by overall volume gain, so this is an important KPI.
Unit reliability is also a very important profitability parameter, and (along with a strong routine maintenance program), many refiners monitor in process operating parameters to ensure that limits are not being exceeded. Some of these parameters are directly measured in the unit, and some are calculated using in-process or mass balanced data.
Measured parameters include unit temperatures (at various points in the unit, including reactor outlet, regenerator bed, reactor and regenerator dilute phases, and others), unit pressures (reactor & regenerator), wet gas compressor suction and power, regenerator emissions, and slide valve / standpipe differential pressures.
Calculated parameters, which are important to monitor, include yield selectivities (yields / conversion), coke make, superficial velocities (especially in cyclones), and catalyst circulation (or cat-to-oil ratio).The recommended ranges for all of these parameters are specific to the FCC unit’s configuration, feed and catalyst type, and operating strategy.
Equilibrium catalyst analysis reports can be a critical tool to monitor FCC unit performance, and to troubleshoot the various problems that can arise in typical FCC unit operation. They are most effectively used when they are incorporated into routine operating reviews with the catalyst supplier. During the reviews, recommendations are often made to adjust operating strategies or fresh catalyst formulation to address future operations or issues that are expected/anticipated for the refinery. These routine reviews are a critical component of the successful operation of the FCC.
The catalyst KPI’s include cracking data (ACE or MAT), physical properties of the catalyst, and chemical analysis of the catalyst. As with yield and operating KPI’s the expectation for these KPI’s varies greatly depending on the feed processed, unit design, catalyst type,and operating strategy of the refinery.In addition, equilibrium catalyst data can be used to benchmark unit performance against similar units, feed types, catalyst types, or a number of other variables. Advanced analytical tools and methods have been developed by catalyst suppliers to understand how age distribution, cyclone performance, contaminant metals, and other variables may impact the performance of the FCC catalyst.
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