FCCU Unit Gernal

8/20/2019 FCCU Unit Gernal

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APPLICATION REPORT

2721 / 07 / 01

EN • 12

/ 2 011

Fluid Catalytic Cracking Unit -FCCU

Process overviewFu Catatc Cacn pocess s an mpotant

an we use wa to convet heav feestoc

nto hte, moe vauabe poucts. Vaous

feestoc can be use, such as as os, vacu-

um as os o esua mateas. Tpca po-

ucts ae asone, ht fue os an oen-ch

ases.

Hot catast fom the eeneato secton ows

n a uze state thouh the se tube nto the

eacto. The ncomn fee toethe wth ec-

cn su meet hot catast, stat vapozn

an cacn n eacto.

Whe the eactons tae pace, coe s fome

on the catast. The spent catast s sepaatefom cace matea an ben eeneate

thouh bunn off the coe. Afte eeneaton,

the catast s sent bac to the eacto wth a ot

of heat absobe n eeneaton phase. The

cace hocabons ente a factonatn tow-

e, whee t s sepaate nto as, ht cce o,

heav cce o an su. The asone pouct

has oo ovea octane chaactestcs sutabe

to be use fo asone benn.

Metso has man vaves nstae n u cata-

tc unts. Ths appcaton buetn escbes the

equements an Metso ow conto soutons

avaabe fo the FCCU.



2721/07/01 EN FlUid CATAlyTiC CrACki Ng UNiT - FCCU

2 APPliCATiON rEPOrT 12/11

Fluid catalytic cracking challengesContinuous catalyst regeneration makes it

possible to manage the high catalyst coking

rate. The constancy of the yields is achieved

by catalyst cycling between reaction and re-

generation, which ensures the reactor is con-

tinuously supplied with freshly regenerated

catalyst, and product yields are maintained

at fresh catalyst levels. It’s critical to con-

trol the regenerator temperature carefully to

prevent catalyst deactivation by overheating

and to provide the desired amount of burn-

off. Reliable and accurate control, on-off and

ESD-valve performance is important for total

process efficiency.

Health, Safety, Environment – Vave ean

poses both an envonmenta an safet ssue

ue to s of e, toxct an voatty of ases.

Emeenc shutown an on/off vaves mustbe abe to pefom the acton n a pocess o

equpment faue.

Top-class products at maximum yield – The

maet cas fo cean petochemca poucts

an hh quat. it s mpotant that the pocess

s stabe, exbe an une conto. Pope

conto vave pefomance n eacto, eenea-

ton an factonaton mpoves the accuac of

thouhput conto an avese affects to the

pant pefomance an aso the ownsteam

pocesses.

Maintenance costs – Ctca vaves n catast

hann an aton pa an exteme m-

potant oe n successfu catast eeneatn

pocess pefomance. Poo pefomn vaves

n the pocess must be sevce because the

w have a ect mpact on the efcenc of the

pocess.

Plant run-time – renees ae oon fo on-

e pant un-tmes snce owntme means po-

ucton osses an s a emaabe cost ncu-

n mantenance costs. Ths eques eabe

equpment an pocess conto.

Metso solutionsWe are all tuned up to answer these chal-

lenges through our refining application

experience and product offering for control,

safety and automated on/off duty that en-

sure high valve performance in fluid catalytic

cracking processes. Our catalyst handling

valves have proven performance history and

are designed for efficient and reliable proc-

ess operation.

Safety – Metso s the on sne souce eme-

enc shutown vave suppe who has the ex-

peence an nowee to combne nteence

wth most eabe vaves, actuatos an smat

contoes. Technoo seectons e ota stem

opeaton an nheent e safe esn ensue

that atest emsson an e safet stanas can

be appe. reabe vaves wth st nteent,

Sil3 appove safet vave contoe an patastoe testn sstem Nees VavguaTM w

ensue that pant emeenc shutown vaves w

awas pefom pope when neee.

Efficiency – Thouhput osses an poo con-

to pefomance w be avoe wth hh pefo-

mance ota vaves. Fow thouh the pocess

unt ma be chane as the nee ases wth

aneabt of 150:1 an futhe wth fu boe ba

vaves. Ou avance nteent ta vave con-

toes fo conto, on-off an ESd appcatons en-

sue hh postonn accuac an fast esponse.Coect vave seecton an szn wth ou Nepof

vave seecton softwae we can assue the best

vave pefomance an pocess conto.

Availability – Smpe ota esns, same

face-to-face mensons, an oba sevce net-

wo an nvento manaement w hep ou

to optmze ou mantenance actvtes. rota

vaves have been n sevce fo sevea eas

wthout equn mantenance an show no sn

of eaae. The poven pefomance of Metso

vaves wth on astn meta seat thtness

an shut-off capabtes maes them an ea

souton fo conto, on-off an ctca catast

hann appcatons.

Reliability – Vave pefomance ten ata

coecte b ou smat vave contoes an

anaze b Nees FeCae, open FdT/dTM

technoo base conuaton an conton

monton softwae, maes t possbe to pect

an espon to mantenance equements an

euce unscheue owntme. Ths ves fu

tanspaenc to the vave pefomance n po-

cess conto.



FlUid CATAlyTiC CrACkiNg UNiT - FCCU 2721/07/01 EN

APPliCATiON rEPOrT 12/11 3

Fluid catalytic cracking applications

1. Stripping steam ow controlChaene – To mantan the catast actvt at

a usefu eve, t’s necessa to eeneate the

catast b bunn off the coe wth hot a. As

a esut, the catast s contnuous move fom

the eacto to eeneato an bac to eac-

to. remann o on the catast s emove b

steam stppn befoe catast entes the een-

eato. The steam supp to the eacto taes

pace at a tempeatue at satuate steam.

The uton steam supp vave has tpca fo-

own enea equements:

❑ Accuate conto to mnmze the steam

consumpton

❑ Nose eucton capabtes

Metso solution ❑ Fneto, eccentc ota pu vave.

Benets❑ We aneabt wth sne vave souton

fo chann steamn nees.

❑ Conto accuac to optmze steam

consumpton.

❑ reabt to ensue effectve o stppn.

❑ Q-tm opton fo nose eucton

❑ Compact pacae wth smat postone

fo conton monton an to nentf

mantenance nees.

Picture 1. Finetrol

2. Air ow controlChaene – The cacn pocess pouces

cabon (coe) whch emans on the catast

patce an ap owes ts actvt. To man-

tan the catast actvt at a usefu eve, t’s

necessa to eeneate the catast b bun-

n off ths coe wth a. reeneaton s a e

pat of the FCC pocess. it’s ctca to conto

the eeneato tempeatue caefu to pevent

catast eactvaton b oveheatn an to po-

ve the ese amount of bun-off. Ths s one

b conton the a ow.

A tpca a tempeatue s aoun 600 °C.

Metso solution ❑ Nesc hh pefomance tpe eccentc sc

vave

Benets❑ goo conto combne wth on astn

thtness

❑ reabe meta seate, b-ectona thtness

fo on fe cce

❑ Hh moua esn an matea seecton

fo ease of mantenance an vave seecton.

❑ Economca conto vave fo ow ffeenta

pessues.

Picture 2. Neldisc

3. Catalyst valvesChaene – Contnuous catast eeneatn

maes t possbe to manae the hh catast co-

n ate. The constanc of the es s acheve

b catast ccn between eacton an een-

eaton, whch ensues the eacto s contnuous

suppe wth fesh eeneate catast, an

pouct es ae mantane at fesh catast

eves. Catast hann vaves pa an mpotant

oe n ensun pope FCC pefomance. reabe

an accuate conto, on-off an ESd-vave pefo-

mance s mpotant fo tota pocess efcenc.

Catast hann vaves have tpca foown

enea equements:

❑ lea fee soaton to avo waste o

nefcent FCC unt pefomance

❑ Meum bu-up esstant esn

❑ reabe opeaton to avo atona spent

catast n eeneato, whch ma cause

possbe catast n ue as an futhe

emsson pobems



2721/07/01 EN FlUid CATAlyTiC CrACki Ng UNiT - FCCU

4 APPliCATiON rEPOrT 12/11

Regenerator extraction valve – The feestoc

s vapoze b the hot eeneate catast, the

cacn bens, an the esutant vapo caes

the catast upwa thouh the se. The heat

of combuston ases the catast tempeatue to

(620 – 845 °C), an most of ths heat s tans-

fee b the catast to the o fee n the fee

se. The eeneato/eacto cce contnues

unt catast s spent an emove fom pocess

thouh extacton vave. A tpca tempeatue

hee s 760 °C.

Flue gas catalyst separation valves – Hot ue

ases ext the eeneato thouh ccones

whee catast s sepaate an ecce to e-

acto. A tpca tempeatue hee s 760 °C.

Metso SolutionNees seat suppote ba vave wth so poof

seat. The Nees J tpe sos poof seats pe-vent catast ust fom ettn behn the seats

that pecues the possbt of toque ncease.

The seats pove constant oan between the

seat an the ba to be n contnous contact. The

mateas of constucton ae seecte fo max-

mum esstance to abason amae aown

fo on cce fe.We ecommen to use speca

ha coatns on ba an seat sean sufaces.

Benets❑ Safet, on astn thtness an cce fe

❑ reabe opeaton wth wpn seat esn ❑ Emsson poon wth ota technoo an

stana ve oae pacn

❑ Fe poven pefomance

❑ No cavtes to et catasts tappe

Picture 3. Neles seat supported ball valve

Catalyst addition valves – Each a, sev-

ea tons of fesh catast ae ae to epace

osses thouh the ccones an to mantan the

actvt of the unt’s nvento at an acceptabe

eve. A tpca tempeatue hee s ambent.

Metso Solution❑ Jamesbu 9150 sees soft-seate ba vave

wth Xteme seats has pove to be the ht

choce as catast aton vaves.

As an opton to tatona soeno vave an

mt swtches, Metso can offe aso nteent

on-off vave contoe Nees Swtchgua, that

ves the possbt to conto the vave open-

nn an cosn stoes an aso poves a-

nostcs about the vave pefomance.

4. Fractionator bottom slurry valves

Challenge – The emann heav esua o,toethe wth an catast caove, coects

at the bottom of the factonato an ecces

bac to the eacto fo the catast to be use n

the eacto. Bottom ecce s use to ecove

heat fo fee peheat thouh ette boes an

exchanes. The u s nown as catast o

su an ts conto an soaton, ue to ts

hh abasve natue an tempeatue, pove

a emann vave appcaton. The tpca tem-

peatue of bottom su s 370 °C.

Picture 4. Finetrol

Metso Solution for control valves❑ Fneto eccentc pu vave wth stete

seat constucton an ow to cose ecton

❑ E-sees ceamc vave n exteme eosve

cases

Benets ❑ rota technoo fo ow emssons

❑ lon cce fe

❑ Eoson esstant esn fo both meum an

hh eosve appcatons



FlUid CATAlyTiC CrACkiNg UNiT - FCCU 2721/07/01 EN

APPliCATiON rEPOrT 12/11 5

Metso solution for on-off valves ❑ Nees seat suppote ba vaves XA wth

hh tempeatue meta seats.

Benets ❑ rota technoo fo ow emssons

❑ lon cce fe

❑ Eoson esstant esn

5. Expander valvesThe ue as fom the FCC pocess extn the

eeneato has sncant pessue, tempea-

tue an voume, an t s a souce of usefu

ene that epesents an ene cost-savn

oppotunt to a ene. Usn an expane

cou maxmze ecove of avaabe ene

fom the ue as. Ths ene can then be use

to ve the compesso that poves a to the

eeneato (the man a bowe) o an eectc

eneato.

Challenge – The expane vaves shou be

abe to wo une ve hh tempeatue (up to

760 °C). The ue as ma entan some aba-

sve catast patces. Fast cosn / openn,

sutabe shut-off capabtes an eabt ove

on peos ae eque. Hue thema shoc

an nconstant tempeatue un the emeen-

c case ma ea to estuctve hh pessue

oae on seat b sc.

Expander inlet valve – in noma sevce theexpane net vave contos the upsteam

pessue to ensue the constant pessue of the

eeneato. The vave shou be abe to cose n

ess than 0.6 secons fom an open poston.

Main bypass valve – in noma sevce the

man bpass vave emans fu cose. The

vave shou be abe to open n ess than 0.6

secons n case of an expane tp.

Small bypass valve – The sma bpass vaves

s use fo snchonzn the expane an

ovespee conto. in noma opeaton the sma

bpass vave emans n an ntemeate con-

to, an sha be abe to fu open n ess than

1 secons n a case of expane tp. dene

sma eaae mht be eque n case the ppe

coo too much potenta beow the ew pont.

Hue thema shoc an nconstant tempeatue

un the emeenc case ma ea to estuc-

tve hh pessue oae on seat b sc.

Metso solution❑ Stana an hh tempeatue appcatons

Mapa butte vave TyPE BW fo eaae

casses V & Vi

❑ Stana an hh tempeatue appcatons

Mapa butte vave TyPE Bd fo eaae

casses ii, iii, & iV

❑ Nees Tpe eccentc sc vave fo owe

tempeatue appcatons (up to 600 °C)

Benets❑ Speca apetue bns seat eement n oo

opeaton conton

❑ Speca apetue on mantenance, n

BW case, seat an sean eement s

chaneabe

❑ Speca esne exbe seat aanst

thema shoc an avo ovestess

❑ Customze enneen esn abt

❑ lon cce fe ❑ Eoson esstant esn

Picture 5. Mapag type BW valve



The nfomaton pove n ths buetn s avso n natue, an s ntene as a uene on.

Fo specc ccumstances an moe etae nfomaton, pease consut wth ou oca automaton expet at Metso.

Metso Automation Inc.

Europe, Vanha Porvoontie 229, P.O. Box 304, FI-01301 VANTAA, Finland.Tel. +358 20 483 150. Fax +358 20 483 151

North America, 44 Bowditch Drive, P.O. Box 8044, Shrewsbury, MA 01545, USA.Tel. +1 508 852 0200. Fax +1 508 852 8172

South America, Av. Independéncia, 2500- Iporanga, 18087-101, Sorocaba-São PauloBrazil. Tel. +55 15 2102 9700. Fax +55 15 2102 9748/49

Asia Pacific, 20 Kallang Avenue, Lobby B, #06-00, PICO Creative Centre, Singapore 339411, Singapore.Tel. +65 6511 1011. Fax +65 6250 0830

China, 19/F, the Exchange Beijing, No. 118, Jianguo Lu Yi, Chaoyang Dist, 100022 Beijing, China.Tel. +86-10-6566-6600. Fax +86-10-6566-2575

Middle East, Roundabout 8, Unit AB-07, P.O. Box 17175, Jebel Ali Freezone, Dubai,United Arab Emirates. Tel. +971 4 883 6974. Fax +971 4 883 6836

www.metso.com/valves

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FCCU Unit Gernal

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