fcc f d i j ti t h lfcc feed injection...
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FCC F d I j ti T h lFCC F d I j ti T h lFCC Feed Injection TechnologyFCC Feed Injection Technology
Paul D. Wendt
FCC Technology Manager
L T h lLummus Technology
CatCracking com Safety & Reliability SeminarCatCracking.com Safety & Reliability Seminar
Galveston, May 2012
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Feed Injection TechnologyFeed Injection Technology
• Why So Important?
P Obj ti• Process Objectives
• Development History
• Key Design Considerations• Key Design Considerations
• Micro-Jet™ Injector Features
• Commercial Examplesp
• Areas of Focus
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FCC Feed Injection FCC Feed Injection -- The Big PictureThe Big Picture
• Critical starting point for the conversion processDiffic lt to reco er from a non optimal starting point– Difficult to recover from a non-optimal starting point
• Continuously impacts the value generation from the unit
• Easy to operate and monitor
• Multiple technology advances across 70 years f FCC hi tof FCC history
• Typically easy to revamp and upgrade
• Relatively low investment cost and quick• Relatively low investment cost and quick payouts
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Effect on FCC PerformanceEffect on FCC Performance
• Directly impacts the conversion and overall yield performance of the unityield performance of the unit– Dry Gas yield
– Liquid yield
– Delta coke / Regenerator temperature
• Feed circuit capacity / hydraulics
• Steam usage / sour water production• Steam usage / sour water production
• Equipment erosion
• Equipment cokingEquipment coking
• Catalyst attrition
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Process ObjectivesProcess Objectives
• Provide thorough and uniform contact of the feed with the regenerated catalyst g y– Essential for the required heat transfer
– Provides access of the feed molecules to the catalyst active sitesactive sites
• Provide instantaneous feed vaporization– Critical to achieve desired reaction paths and yields
– Inhibits thermal cracking reactions that increase dry gas and coke
• Minimize oil side pressure dropp p– Maintain capacity through the feed preheat circuit
• Provide wide range of operationf f
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– Maintain performance from turndown to max throughput
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Process ObjectivesProcess Objectives
• Maximize the surface area contact between the oil feed and circulating catalystg y– Surface area maximized by dividing the liquid feed
into small droplets
– Condition of circulating regenerated catalyst alsoCondition of circulating regenerated catalyst also critical
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Development History Development History
There has been considerable evolution in feed injection technology over the last 7 decades:
• Open pipes• Open pipes– Used in early FCC unit designs
– Axial injection at bottom of the riser
– Single pipe, multiple pipes (i.e. Christmas Tree)
– Multiple pipes with common cap (Showerhead)
• Open pipes radial injectionOpen pipes, radial injection – Multiple open pipes located farther up the riser
– Lift or fluidization steam at riser bottom
C– Cone spray
• Slotted cap, radial injection– Flat fan spray, single point contact of the catalyst
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Flat fan spray, single point contact of the catalyst and feed
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Development History Development History
Open Pipes, Axial Showerhead, Axial Elevated, Radial
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Open Pipes, Axial Showerhead, Axial Elevated, Radial
Development History Development History
• Slotted caps, two levels, radial injection – Second level to contact the catalyst that might
escape the first le elescape the first level
• Slotted caps atomizing Injectors– Impact-type of injectors, use of high pressure to p yp j g p
atomize the feed
– Single level radial injection
– Two slots in the cap instead of oneTwo slots in the cap instead of one
• Multiple openings in the cap, atomization with moderate feed pressure– Multiple orifices in the cap to distribute feed evenly
across the cap
– Flat fan spray
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– Use energy of steam to atomize the feed
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Key Design ConsiderationsKey Design Considerations
• Efficient feed atomization– Formation of smaller droplets to support catalytic
reactions and heat transferreactions and heat transfer
– Uniform droplet size for consistency
• Low oil side pressure drop to produce the atomization
40000
45000
15000
20000
25000
30000
35000
40000
Freq
uenc
y
0
5000
10000
15000
0.1 0.8 8.0
Relative Droplet DiameterIncreasing Droplet Diameter
Inc.
F
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Key Design ConsiderationsKey Design Considerations
• Thorough contact of the feed and catalyst across entire riser cross-sectionacross entire riser cross section– Optimal number of injectors
– Optimal injection angle
I j t tt– Injector spray pattern
• Optimal exit velocity– Provide velocity for required jet penetrationProvide velocity for required jet penetration
– Minimize catalyst attrition and erosion
• Efficient use of steam
• Minimize potential to plug
• Protection of the injector tip
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Key Design ConsiderationsKey Design Considerations
• Minimize injector erosion (internal and external) to maximize reliability– Optimal exit velocity
– Robust mechanical design
– Account for specific riser design and operationAccount for specific riser design and operation
• Provide for ease of injector extraction from nozzle / sleeve
• Condition of circulating catalyst is critical to effectiveness of the feed injectors– Catalyst density and fluidization profile across riserCatalyst density and fluidization profile across riser
– Uniform mixing and cat/oil across riser
– Must evaluate in unison with the injectors
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MicroMicro--Jet™Jet™ Feed InjectorFeed Injector
• Proprietary tip design to deliver flat spray patternflat spray pattern
• Three stage atomization– Liquid atomization
– Liquid droplets further sheared by steam
– Flat fan spray into catalyst stream
• No use of lift steam – only minimal fluffing steam
L il f d i j ti• Low oil feed injection pressure
• Special metallurgy and tip design for improved reliability
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for improved reliability
MicroMicro--JetJet Feed InjectorFeed Injector
Benefits include:
• Increased conversion and yield of valuable light products
• Low delta coke – ability to process heavier feed and / or similar advantagesfeed and / or similar advantages
• No loss of performance at turndown
• Robust and durable
• Every injector spray tested
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MicroMicro--JetJet Feed Injector Spray Test Feed Injector Spray Test
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Potential Injector LayoutPotential Injector Layout
A A
SECTION A-A
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3D Piping Model Shot3D Piping Model Shot
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Feed Injector RevampFeed Injector Revamp
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Commercial Examples Commercial Examples
Refinery A
Replaced atomizing feed injector with high dP
Pre-Revamp Post-revamp
requirement
Pre Revamp Post revamp
Yields, vol%LPG Base +1.7 Gasoline Base +1 3Gasoline Base +1.3 Conversion Base +2.1
Feed Booster In use ShutdownPump
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Commercial Examples Commercial Examples
Refinery B
Replaced atomizing feed injector and riser
Pre-revamp Post-revampYields, vol%: LPG Base +2 0LPG Base +2.0 Gasoline Base +4.5 Conversion Base +4.1
Reg Temp Base 10 FReg. Temp Base -10 F
Lift Steam in use not needed
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Commercial Examples Commercial Examples
Refinery C
Replaced multiple pipe, non-atomizing injectors
REGENERATOR TEMP vs FEED CCR
710
715
720
g C
700
705
710T
EM
P., d
eg
OLD FEED INJECTOR
690
695
1.2 1.4 1.6 1.8 2 2.2 2.4
RE
G. INJECTOR
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FEED CCR
Areas of FocusAreas of Focus
• Further reliability improvements to mitigate injector erosioninjector erosion– Extend run times before replacement
– Metallurgical advancements
C i– Ceramics
• Use of CFD modeling in design practices– Advancement in CFD tools have made thisAdvancement in CFD tools have made this
practical
– Also used to validate field observations
• Ease of injector extraction• Ease of injector extraction
• Next generation advancements
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Thank You!
Paul D. Wendt
FCC Technology Manager
Lummus Technology
(713)375-8358
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