Professional Documents
Culture Documents
00
q Institution of Chemical Engineers
model for a uid catalytic cracking (FCC) unit which describes the dynamic behaviour
of the riser, particle separator vessel, and the regenerator is developed. The model
consists of coupled ordinary differential equations. This facilitates the solution of the
equations and makes the model particularly suitable for control studies. A sensitivity study is
carried out to determine the interactions between the three controlled and manipulated
variables and the elements of the Bristol1 relative gain array matrix. The relative gain array
analysis suggested that the temperature at the top of the riser, the pressure drop between the
particle separator vessel and the regenerator, and the catalyst holdup in the particle separator
vessel should be controlled by manipulation of the ow rates of the regenerated catalyst, ue
gas from the regenerator, and the spent catalyst leaving the particle separator vessel,
respectively. Three PI-controllers were used to achieve reasonable control of the process.
Keywords: dynamic modelling; FCC unit; riser-regenerator modelling; FCC control;
numerical simulation
INTRODUCTION
Fluid catalytic cracking process is one of the most
extensively used operations for the conversion of gas oil
and certain atmospheric residues to higher octane gasoline.
The unit consists of two reactors, the riser reactor, where
almost all the endothermic cracking reactions and coke
deposition on the catalyst occur, and the regenerator reactor,
where air is used to burn off coke. The regeneration process,
in addition to reactivating the catalyst pellets, provides the
heat required by the endothermic cracking reactions. The
development of new, highly active cracking catalysts, and
the introduction of the additives which greatly enhance the
productivity and the selectivity of the catalyst, allow the
cracking reactions to be completed in the riser. The particle
separator vessel acts as a disengaging chamber to separate
the catalyst from the gaseous products by stripping steam.
The complexity of the FCC unit, from both the process
modelling and control points of view, is attributed to the
strong interactions between the riser and the regenerator
reactors, and the uncertainty in the cracking reactions, coke
deposition and coke burning kinetics. This complexity
together with the important economic incentives, provide
reasons for the extensive research work being performed on
the design and operation of the FCC units.
The literature is relatively rich in the modelling and
simulation investigations of the uid catalytic cracking
units2 6 . Most of these investigations are based on empirical
or semi-empirical models, and present a number of con icting views. The empirical nature of these models limits their
predictive capabilities, and their use in studying and
analysing the behaviour of industrial FCC units. Elnashaie
401
402
ALI et al.
a minimum and retains the dominant dynamic characteristics of the unit. The selection of this type of the uid
catalytic cracking process is due to its popularity in industry.
The kinetic parameters for coke burning over cracking
catalysts obtained by Morely and de Lasa1 9 - 2 0 were used.
There are ve kinetic schemes available in the literature for
the cracking reactions. Two schemes were investigated in a
previous contribution2 1 , the three-lump scheme2 2 and the
four-lump scheme2 3 . Our conclusion was that the use of the
four-lump scheme gives more reliable and better prediction
of the plant data.
A sensitivity study utilizing the open-loop responses of
major process variables is carried out to verify the
interactions between the three controlled and manipulated
variables and the elements of the Bristol s relative gain
array matrix1 . The calculated values of the relative gain
array showed that the existing control con guration at the
unit under investigation has the appropriate pairing of the
manipulated variables and the controlled variables. Three
PI-controllers with parameters estimated by Lee s method2 4
are used to evaluate the control scheme. In what follows a
brief description of the model and the open-loop and closedloop simulation results are presented.
THE MODEL
The FCC unit model is based on the schematic ow
diagram presented in Figure 1. It is assumed that gas oil is
converted to gasoline range hydrocarbons, light gases and
coke in the riser reactor, which is considered to be a
transported bed. The uidized bed (the particle separator
vessel) immediately above the riser acts as a disengaging
chamber where vapour products and heavy components are
separated from the catalyst using stripping steam. It is
assumed that the stripping process completely removes the
hydrocarbon gases adsorbed inside the pellets before the
spent catalyst is sent to the regenerator. The ow rate of the
stripping steam is small compared to those of the feed oil
Trans IChemE, Vol 75, Part A, May 1997
MODELLING AND CONTROL OF A RISER TYPE FLUID CATALYTIC CRACKING (FCC) UNIT
403
(1)
gR
2
[(kBC + kBD )yB - kAB yA ] = 0
(3)
(4)
Coke:
dyCR w R AR e gR LR q
dZ FgR
gR
2
[kBC yB + kAC yA ] = 0
(5)
Energy Balance:
w R e gR q gR LR AR
dTR
+ (F cp F cp )t
dZ
SR
s +
gR
gR ref
2
(yA [kAB (D HRAB ) + kAC (D HRAC )
(6)
= B and D
TR (0) = TRf
404
ALI et al.
----------------
= K X P - P
1
(7)
-1
- 0 .5
-----------------
= K X P - P
2
(9)
-1
- 0 .5
d 3p q
gG
(q
-q
gG
gG
)g
(10)
l
where the volumetric ow rate in the emulsion phase, GI G ,
and in the bubble phase, GC G , are:
GIG = Umf AG
(11)
2
=A
GG
ZG - AGG LG (1 - e
dG
(15)
=V
NGT
dTb
dN
Tb GT
+
ds
ds
PG dV G
- V ds
G
(17)
-------------------
= K X P - P
3
(18)
atm
-1
- 0 .5
=k
=k
cod
0 .5
CCOd CO2d
(20)
cob
0 .5
0.5
CCOb CH2Ob
C02b
(21)
MODELLING AND CONTROL OF A RISER TYPE FLUID CATALYTIC CRACKING (FCC) UNIT
The assumptions imposed on the model equations have
been previously used by Elnashaie and Elshishini1 1 and are
also recommended by Lopez-Isunza and Ruiz-Martinez1 2 .
The energy and coke combustion dynamic terms in the
emulsion phase are taken into consideration, while the
dynamic terms associated with the bubble phase are
assumed negligible due to low solids density in this phase.
Therefore, the bubble phase is considered thermally at quasi
steady-state. Moreover, the homogenous CO combustion
reaction taking place in the bubble phase is assumed to be
negligible in comparison with the catalytic CO combustion
in the emulsion phase1 1 ,1 2 , 2 0 . Based on these assumptions,
the bubble phase equations were solved analytically.
Furthermore, the integral terms appearing in the equations
describing the emulsion phase were evaluated analytically.
The concentrations of various gaseous species in the
regenerator were normalized with respect to the oxygen
feed concentration, and both the bubble phase and the
emulsion phase temperatures were normalized with respect
to the emulsion phase temperature. The nal form of the
regenerator model equations is:
Coke balance(Emulsion phase):
dyCG
LGss
(FsG yCR - FsR yCG
C ky y
ds = AG LG1 (1 - e dG )q S Ua - Ua 02f c CG O2d
yCG dLG1
G1 ds
-L
(22)
= y + eCOd
a1 z
- yCOd )
(yCOf
(23)
Emulsion phase:
a
[GIG + GCG (1 - e - 1 )](yCOf
(24)
sR
CO2 balance:
Bubble phase:
=y
CO2d
a z
+ e - 1 (yCO2f - yCO2d )
(25)
Emulsion phase:
a
[GIG + GCG (1 - e - 1 )](yCO2f
- yCO2d )
.
- 2AG LG1 LGssLGss q b k 9COd yCOd yO2d
AG LG1 LGss q s (1 - e dG )FgR k C9 9
yCG YO2d = 0
MW F
05
(26)
sR
O2 balance:
Bubble phase:
yO2b
= y + eO2d
Length (m)
Diameter (m)
33
11
0.8
5.8
Riser Reactor
Regenerator Reactor
Energy balance:
Bubble phase:
Tb
= T + ed
a hz
(Tairf
- Td )
(29)
Emulsion phase:
dTd [GIG + GCG (e a h z - 1)]q gG cp gG
(Tairf
ds =
AG LG1 (1 - e dG )q s Ua cpS
- Td )
FsG
+ A L (1 e )q U (TR - Td )
G G1
- dG s a
F L C
gR Gss O2f C
- HlG + F U cp t yCG yO2d (D HRC )
sR a
S ref
(30)
1.5
2LGss q b CO2f
+ (1 e )q U cp t
- dG S a S ref
.5
* kCOd yCOd y0O2d
(D HRCOd ) -
Td dLG1
LG1 ds
a 1z
(yO2f
Td (0) = TdSS
- yCOd )
0 .5
C0d
yCO2b
CO balance:
Bubble phase:
yCOb
405
- yO2d )
(27)
Emulsion phase:
[GIG + GCG (1 - e - a 1 )](yO2f
yO2d )
0 .5
O2d
(28)
=0
Gas oil
Air
Catalyst
20
16
144
494
378
406
ALI et al.
8.4 kg m 3
3.299 kJ kg- 1 K- 1
2.671 kJ kg- 1 K- 1
156 kJ kg- 1
698 K
710 Cal g- 1
2328 Cal g- 1
5693 Cal g- 1
1618 Cal g- 1
5403 Cal g- 1
Air:
Density:
Speci c heat:
Bubble-emulsion mass transfer coeff.:
Bubble-emulsion heat transfer coeff.:
1.03 kg m 3
1.206 kJ kg- 1 K- 1
0.5 sec 1
0.84 kJ sec- 1 m 2 K- 1
Catalyst:
Bulk density:
dp (particle size):
Heat capacity:
Inventory in the regenerator:
970 kg m 3
75 10 6 m
1.15 kJ kg- 1 K- 1
5000070000 kg
Pre-exponential
constant
Activation Energy
(kJ / mol1)
224.99
70.74
Pre-exponential
constant
Activation Energy
(kJ/mol- 1 )
68.2495
64.5750
89.2164
115.458
52.7184
Model
Riser reactor
Gasoline yield, wt%
Coke wt%
Riser temp, K
Regenerator reactor
Regen. temp, K
CO2, Mol%
O2, Mol%
Plant
%dev.
42.7
6.1
749
43.9
5.8
795
2.7
4.4
5.8
939
17.4
3.7
960
17.7
3.0
2.2
1.6
18.5
MODELLING AND CONTROL OF A RISER TYPE FLUID CATALYTIC CRACKING (FCC) UNIT
407
408
ALI et al.
Figure 5. Transient response of the spent catalyst ow rate and the catalyst
bed level in the particle separator vessel to step increase and decrease in the
spent catalyst valve position.
Figure 7. The control con guration used for the FCC unit.
MODELLING AND CONTROL OF A RISER TYPE FLUID CATALYTIC CRACKING (FCC) UNIT
409
Kc
I, min
Fine Tuned
Kc
I, min
D t, min
0.001 762.11
0.0007 101.36
0.0009
0.0003
504.32
120.3589
1.24
0.41
0.064
0.0015
8.884
0.083
3.91
Figure 8. Closed loop response to a step increase and decrease in the riser
temperature set-point.
FSR
FSG
(31)
Ffg
5.87
= - 4.87
- 4.87 0
5.87
(32)
410
ALI et al.
Figure 9. Closed loop response to a step increase and decrease in the level
of catalyst in the particle separator vessel set-point.
Figure 10. Closed loop response to a step increase and decrease in the
regenerator pressure set-point.
CONCLUSIONS
MODELLING AND CONTROL OF A RISER TYPE FLUID CATALYTIC CRACKING (FCC) UNIT
NOMENCLATUR E
A
AG
AGG
AR
Arv
av
B
C
Cjb
Cjd
CO2f
cpl
cpgG
cpgR
cps
D
dp
ei, k
Ffg
FgR
FsG
FsR
GIG
GCG
g
HlR
HlG
h
Hrv
hrv
K
Ki
Kc,i
kij
kc
kcob
kcod
k9 c
k9 c 9
k9 c9 9
k9 cod
kg
LG
LGss
LG1
LR
MSG
MWC
MWgG
NGT
Patm
Pf
PG
PR
R
rc
rcod
rcob
Tairf
Tj
TB
TR
tref
t
ta
Ua
Umf
VG
WCG
WCR
X
ya
yCG
yCR
yij
yif
Z
ZR
ZG
ZG1
z
411
Greek letters
a 1
(AG e dG(1-ebG) LGss kg /GCG), see equation (25)
a h
(AG (1-e bG) av h LGss /GCG rgG cpgG), see equation (29)
b
intrinsic molar ratio of CO2 to CO, kmol CO2 / kmol CO
D HRAB heat of reaction for cracking of lump A to lump B, kJ kg- 1
D HRC heat of reaction for coke burning, (kJ kmol- 1 ), see equation (30)
D HRCOj heat of reaction for CO combustion in the j phase, kJ kmol- 1
sampling interval, min
D t
e gR
hydrocarbon gases void fraction in the riser
e bG
bubbles void fraction in the regenerator bed
e dG
emulsion phase void fraction in the regenerator
e mf
bed voidage at minimum uidization velocity
e rv
bed voidage in the particle separator vessel
w
catalyst activity
l
air viscosity, kg (m- 1 sec- 1 )
relative gain matrix
K
q b
catalyst bulk density, kg m 3
q gG
density of gas phase in the regenerator, kg m 3
q gR
density of gas phase in the riser, kg m 3
q s
density of catalyst particles, kg m 3
hs
catalyst particle sphericity
s
dimensionless time, t Ua /LGss
s I,i
integral time of the ith loop, min
Subscripts
b
bubble phase in the regenerator
CO
carbon monoxide
CO2
carbon dioxide
d
emulsion phase in the regenerator
f
feed
G
regenerator reactor
g
gas phase
H2O
water vapour
O2
oxygen
R
riser reactor
rv
particle separator vessel
S
catalyst solid particles
ss
steady-state
REFERENCES
1. Bristol, E. H., 1966, On a new measure of interaction for multivariable
process control, IEEE Trans Autom Control, AC-11: 133134.
2. Kurihara, H., 1967, Optimal control of uid catalytic cracking
processes, PhD Thesis, (MIT, Cambridge, USA).
3. Iscol, L., 1970, The dynamic and stability of a uid catalytic cracker,
Proc Joint Automatic Control Conf, Atlanta, Georgia, 602607.
4. Lee, W. and Kugelman, A. M., 1973, Number of steady-state operating
points and local stability of open-loop uid catalytic cracker, Ind Eng
Chem Proc Des Dev, 12 (2): 197204.
5. Lee, E. and Groves, F. R., 1985, Mathematical model of the uidized
bed catalytic cracking plant, Trans Soc Comp Sim, 2: 219236.
6. Edwards, W. M. and Kim, H. N., 1988, Multiple steady state in FCC
unit operations, Chem Eng Sci, 43: 18251830.
7. Elnashaie, S. S. E. H and El-Hennawi, I. M., 1979, Multiplicity of the
steady state in uidizied bed reactors-IV. Fluid catalytic cracking
(FCC), Chem Eng Sci, 34: 11131121.
8. Elshishini, S. S. and Elnashaie, S. S. E. H., 1990, Digital simulation of
412
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
ALI et al.
21. Ali, H. K. A., Rohani, S., 1995, Effect of cracking reactions kinetic
scheme selection on the model prediction of an industrial uid catalytic
cracking unit, Chem Eng Commun, (in print).
22. Weekman, V. W. and Nace, D. M., 1970, Kinetics of catalytic cracking
selectivity in xed, moving, and uid bed reactors, AIChE J, 16: 397
404.
23. Lee, L-S. , Chen, Y-W. , Haung, T-N. and Pan, W-Y. , 1989, Four lump
kinetic model for uid catalytic cracking process, Can J Chem Eng, 67:
615619.
24. Lee, J., 1989, On-line PID controller tuning from a single, closed-loop
test, AIChE J, 35: 329331.
25. Consumers Co-operative re neries Ltd., Regina, Saskatchewan,
Canada, 1994, (private communications).
26. Theologos, K. N. and Markatos, N. C., 1993, Advanced modeling of
uid catalytic cracking riser-type reactors, AIChE J, 39: 10071017.
27. Kunii, D. and Levenspiel, O., 1991, Fluidization Engineering,
(ButterworthHeinemann Publishers, MA, USA).
28. API Technical Data Book Petroleum Re ning, 1967, (American
Petroleum Institute (API)).
29. Perry, R. H. and Chilton, C. H. (Eds), 1973, Chemical Engineers
Handbook, (McGraw Hill, New York, USA).
30. Gear, C. W., 1971, Numerical Initial-Value Problems in Ordinary
Differential Equations, (Prentice Hall, Englewood Cliffs, NJ, USA).
ADDRESS
Correspondence concerning this paper should be addressed to Professor
S. Rohani, Laboratoire des Sciences du Genie Chimique, BP451-1, rue
Grandville, Nancy Cedex, France.
The manuscript was communicated via our International Editor for
Canada, Professor M. H. I. Baird. It was received 28 February 1996 and
accepted for publication after revision 8 November 1996.