FCC UNIT

Scientific Reports 2024

By :Scientific committee of BUOG AICHE
CONTENTS
-Introduction
-What is the FCC unit? What is its main goal?
-What are the types of FCC units?
-Can the FCC unit convert all kinds of heavy ores into useful products in the
oil and gas sector?
-process
-What are the best ways to deal with catalyst contamination in the FCC unit?
-Improve FCC efficiency and reduce energy consumption
-Comparing the FCC unit with other cracking operations
-Risk
-Global developments in the field of the FCC unit, new uses, and industrial
challenges
-Design
INTRODUCTION
The FCC (Fluid Catalytic Cracking) unit is an important
process in the petroleum refining industry. This unit is
used to convert heavy oils with low heating value into a
variety of valuable products such as gasoline, diesel, and
liquefied natural gas.
The history of the FCC unit dates back several decades. This
technology was first developed in 1942 at the Universal Oil Products
(UOP) by the American chemist Whitney J. Lewis. In 1943, Lewis' patent
for the FCC cracking process was licensed.
Over time, the FCC unit has evolved and improved to enhance
conversion efficiency and increase productivity. Today, the FCC unit
is considered a fundamental element in petroleum refining refineries.
Over time, the FCC unit has evolved and improved to enhance
conversion efficiency and increase productivity. Today, the FCC unit
is considered a fundamental element in petroleum refining refineries.

Over the decades, the design of FCC units has been improved and
developed by many oil refineries and companies. And to continue
meeting the continuous demand for oil products, FCC cracking
technology continues to evolve and innovate to meet global market
needs.
Over the decades, the design of FCC units has been improved and
developed by many oil refineries and companies. And to continue
meeting the continuous demand for oil products, FCC cracking
technology continues to evolve and innovate to meet global market
needs
 What is the fcc unit ? What is its main goal?

The "FCC" unit found in refineries is an acronym for Fluidized catalytic cracking, Which
means breaking chains of hydrocarbons by using a fluidizing catalyst through
reacting the heavy materials produced from the atmospheric and vacuum
distillation tower with the catalyst (alumina silicate).

the goal!
It is the production of a group of gases, but the main goal is the production of a Gas
line, where the percentage of production is From (35_60) in the unit used as fuel for
cars.
 What's are the types of fcc unit ?

1. 3.
HYDROCRACKING UNIT: VISBREAKING UNIT:
Used to convert coal or heavy oils into lighter, Used to convert heavy oils and asphalt into
more valuable products such as gasoline and higher-value products, usually in the marine
diesel. This unit requires high pressure high fuel and combustible fuel industry.
temperatures and the presence of hydrogen.

2. 4.
HYDROISOMERIZATION UNIT: POLYMERIZATION UNIT:
Used to convert heavy oil into lighter, more Used to convert light olefins into more
valuable oils such as aviation oils and lubricants. valuable polymers such as polyethylene and
This unit works by improving the molecular polypropylene. These polymers are used in
composition of the oil and reducing the sulfur many applications including the manufacture
and nitrogen content. of plastics, textiles, and membranes.
Can the fcc unit convert all kinds of heavy ores
into useful products in the oil and gas sector?

The Fluid Catalytic Cracking (FCC) unit is typically used to extract oil and gas from shale or
sandstone rocks, contributing to good productivity. However, it is not suitable for converting all
types of heavy raw materials into useful products in the oil and gas sector.

Heavy raw materials include oil sands, asphalt, and non-siliceous heavy oils, which usually require
complex and costly refining processes to extract valuable products. For example, in the case of oil
sands, extraction requires a process of heating and chemical treatment to size the sand before
extracting the oil.

Therefore, different techniques are used to convert heavy raw materials into usable products in the
oil and gas sector, such as heavy refining processes and advanced petrochemical techniques.
These processes require certain equipment and technologies, consume significant energy, and
require precise study and evaluation of local and economic conditions.
FCC unit Consisting of

▪️ RISER OR RECTOR
It is a reactor in which the reaction between the
incoming heavy materials and the catalyst takes place

▪️ REGENERATOR
Which reactivates the catalyst after the reaction has
occurred so that the process will be continuous

▪️ FRACTIONATOR COLUMN
It is a tower that separates the materials that come out of
the Rector into a group of gases
PROCESS From the bottom of the air
distillation tower comes the heavy material called
residue, and from the vacuum distillation tower
vaccum gas oil will be introduced from the bottom into
the Rector and the catalyst (alumina silicate) comes,
which is small balls or in the form of particles that have
been reactivated and have high temperatures It meets
the feed, which is high fluoride, in large quantity, and a
temperature of more than 350C, as these balls of the
catalyst will run with the liquid, but will not dissolve in it,
but will behave like a liquid, so the catalyst here will be
fluidized because the behavior of the catalyst used
here Type of . Molecular Sev, which allows the entry of
molecules and does not allow others to enter, and the
reaction time will be from 2 to 10 minutes. A group of
products will come out and go to the fractionator
tower, which separates the products into a group of
gases
- (dry gas ,LPG , Gasoline ,LCO ,HCO ,Coke)
What are the best ways to deal with catalyst
contamination in fcc a unit ?
Catalyst contamination in an FCC (Fluid Catalytic Cracking) unit can be a significant challenge in the oil
refining industry. It is good to seek the best ways to deal with this pollution to improve the performance
of the unit and reduce the costs resulting from it. Here are some common approaches that can be
taken:

1. Improve the quality of the crude oil:

The catalyst pollution can be reduced by improving the quality of the crude oil used. Crude oil must be
selected with a suitable composition and contain a low percentage of oxidized pollutants and heavy
metals.

2. Routine maintenance:
Routine maintenance of the FCC unit must be carried out regularly to maintain the efficiency of the
catalyst and reduce the possibility of contamination. Sediment and impurities should be cleaned and
removed regularly.

3. Separation optimization:
The separation process inside the FCC unit can be optimized to reduce catalyst contamination.
Advanced control devices and technologies such as efficient heat exchange and quick separation can
be used to improve unit efficiency.

4. Improving catalyst properties:

High-quality catalysts with improved formulations can be used to reduce catalyst contamination.
Advanced catalysts are being developed to be more sustainable and resistant to contamination.
What are the best ways to deal with catalyst
contamination in fcc a unit ?
5. Process monitoring and analysis:
Careful FCC process monitoring and analysis should be carried out for early detection of any change in
catalyst quality or contamination. This early detection enables rapid intervention and corrective action.

6. Training and Awareness:

Operators and technicians must be properly trained to understand how to properly handle the FCC unit
and to recognize potential signs and symptoms of contamination. This helps improve the team's ability
to deal with pollution effectively.

These methods must be used together and in an integrated manner to obtain the best results in
managing catalyst contamination in the FCC unit. It may be best to consult with experts in the field to
provide appropriate expertise and guidance to improve the performance of your FCC unit.
How to improve FCC unit efficiency and reduce
consumption energy?
1. Improved catalyst quality:
High-quality activation and improved properties can lead to increased conversion and reduced
loss. This allows controlling its properties and characteristics and increasing its effectiveness
and stability. Catalyst formulations are developed to be used for better performance.

2. Improved FCC module design

This includes optimizing partial, catalyst, and reactive reactor design, and optimizing the control
and operation system. The cooling and heating system is also optimized for optimum
temperature and energy-saving

3. Improved heat management:

Effective heat management is an important part of improving FCC module efficiency and
reducing losses. This can be achieved by optimizing the design of the heating and cooling unit
and the heat distribution in the unit. Images such as images, cooling and optimization are used
to maximize heat utilization and reduce energy consumption.
How to improve FCC unit efficiency and reduce
consumption energy?
4. Control of processes and variables:
The use of advanced and sensitive control devices can lead to efficient FCC units. Proper
functioning such as temperature, pressure, and catalyst flow must be ensured to accurately
control air and fuel at optimum performance under inactive conditions that lead to energy loss.

5. Training and Education:

Providing training for new releases and raising awareness of specifics and practices in the FCC
unit's field that could also be improved. By training the technical operators on how to maintain
and maintain the exquisite units, good performance can be achieved at the lowest costs.

These nutrients must be fully implemented and balanced to achieve overall efficacy in the FCC
Catalytic Unit and to reduce energy loss and expenditure. Factors specific to the requirements
and conditions of a particular refinery and the objective to be improved must also be taken into
consideration
RISK
1. Personal safety: The work of the FCC unit involves a set of dangerous processes and chemical
reactions that require strict caution. Workers may be at risk due to extreme heat, high pressure, and
hazardous chemicals used in the process. Workers must wear appropriate protective clothing and
equipment and follow safety procedures and necessary training.

2. Fires and explosions: Due to the high heat and strong chemical reactions inside the FCC unit, there is
a risk of fires and explosions. Effective fire prevention measures and fire extinguishing systems must be
provided, in addition to continuous monitoring of heat and pressure inside the unit.
3. Hazardous material leaks: Leakage of the hazardous chemicals used in the FCC unit may occur,
posing a risk to the environment and public health. Strict procedures must be implemented to
minimize hazardous material leakage and carefully clean the environment.

4. Environmental pollution: The FCC unit can emit harmful gases and pollutant particles into the air.
Gas and residue treatment systems must be installed to minimize environmental impact and comply
with environmental standards.

5. Operation and maintenance problems: The FCC unit includes many equipment and systems that
need effective maintenance and management. Unexpected operational problems or technical
accidents may occur affecting unit efficiency and personnel safety.
Global developments in the field of the FCC unit,
new uses, and industrial challenges
▪️ INTERNATIONAL DEVELOPMENTS IN THE FIELD OF FLUIDIZED CATALYTIC CRACKING:
➖️1. Improving process efficiency: Work is being done to improve the efficiency of the fluidized stimulus
cracking unit operations by improving the technology used and developing chemical catalysts to
increase the productivity of the units.

➖️2. Advanced Technology: Some units rely on advanced technology such as the use of nano-
technology catalysts and intelligent control systems for accurate optimization of crushing processes.

➖️3. Product Diversification: Focus is on FCC product diversification to meet diversified demand in the
oil and gas market, with a shift towards higher value products such as kerosene fuels, condensate and
versatile chemicals.

➖️4. Environmental improvement: The oil and gas sector is working on developing fluidized catalytic
cracking units to improve environmental performance and reduce emissions of harmful gases, by-
product oils and waste.
Global developments in the field of the FCC
unit, new uses, and industrial challenges
▪️ INDUSTRIAL CHALLENGES:
➖️1. Adapting to environmental standards: The fluidized catalytic cracker industry faces challenges in
adapting to strict environmental standards, which require the reduction of harmful gas emissions and
other environmental impacts.

➖️2. Investment costs: Fluidized catalytic crackers involve a high investment and require continuous
operation and maintenance. Finding the perfect balance between high performance and sustainable
costs is required.

➖️3. Risk control: The use of crushing units involves security, health and environmental risks, such as
handling hazargdous materials, ensuring worker safety, and protecting against accidental accidents.

➖️4. Operational Challenges: Fluidized stimulus cracking units require continuous operation, close
monitoring of operations, maintaining efficient performance, and providing regular maintenance.
Global developments in the field of the FCC unit,
new uses, and industrial challenges
NEW USES AND INDUSTRIAL CHALLENGES IN THE FLUIDIZED CATALYTIC UNIT:

🔷1. Use of multiple catalysts: New techniques are being developed to use multiple catalysts in a
fluidized catalyst unit. This opens up new opportunities for the transformation of various chemical
compounds and product diversification.

🔷2. Nanotechnology: Nanotechnology is used in the fluidized catalyst unit to improve process
efficiency and increase the surface activity of the catalysts, leading to increased productivity and
improved product quality.

🔷3. Natural Gas Conversion: The fracking segment is developing fluid catalytic cracking units to
convert natural gases into valuable products such as base chemicals and fuels.

🔷4. Uses in the renewable energy industry: Fluidized catalysts are used to convert various biomaterials
and organic waste into biofuels and chemical products usable in the renewable energy industry.
DESIGN

1. Basic planning and design:

This includes determining the size and capacity required for the unit based on the type of oil to be
refined and the needs of the market. It also determines where to direct the unit within the refinery and
makes sure that the necessary space and infrastructure are available.

2. Engineering details:
This step involves defining details of the schedules, piping, and equipment needed. The pressures,
temperatures and materials used must be considered to ensure the safety and efficiency of the unit.

3. Selection of Equipment and Materials

Equipment such as reactors, heat exchangers and piping suitable for the refining process must be
selected. Materials that are resistant to corrosion and high pressures should also be selected.
DESIGN
4. Control and Automation:
This includes automated data collection and process monitoring to ensure maximum efficiency and
safety. SCADA and PLC systems can be used for this.

5. Operation and Maintenance:

Once the unit has been installed, it must be tested and operated safely. A plan must be put in place
for routine maintenance and long-term repairs.

6. Compliance with the environment and safety:

Environmental and safety standards must be adhered to during the design and operation of the unit,
to maintain the safety of workers and the surrounding environment.

7. Continuous Improvement:
The performance of the unit should always be reviewed and ways to improve its efficiency and
reduce waste should be looked for.

Collaboration of mechanical, chemical, electrical, and civil design engineers is required to ensure an
efficient and safe FCC unit design.
Scientific Reports 2024