August 2007

Process Developments

Fine-tune catalyst addition rates

Simple method dynamically optimizes E-catalyst activity in fluid catalytic crackers

Choudary, N. V., Gokak, D. T., Murali, C., Ravichander, N., Voolapalli, R. K., Bharat Petroleum Corp. Ltd.; Siddiqui, A., Engineered Project Services LLC

The operation of the fluid catalytic cracker (FCC) unit depends on many factors. A critical operating performance factor is catalyst addition. Loss of catalyst activity severely compromises this unit's operation and product yields. This case history explores opportunities to optimize catalyst addition rates for FCC units. Background. Severe hydrothermal conditions prevail in the FCC reactor-regenerator system, and metal contamination from unit feed decreases activity of FCC catalyst. To maintain the desired activity level for the catalyst inventory, equilibrium catalyst (Ecat) is continuously purged from the unit, often on a daily basis, and replaced with fresh catalyst. Catalyst cost is

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