The reduction of FCCU afterburning through process optimization and regenerator revamping

Operating the fluid catalytic cracking unit (FCCU) in afterburning conditions can increase regenerator temperatures above metallurgical design leading to mechanical failures of cyclones and plenum chamber. This paper presents methodology applied a commercial FCCU investigate causes technical solutions that be implemented reduce afterburning. Thus, by evaluating temperature profile, as-build design, internals status, it was concluded main cause non-uniform distribution mixing air catalyst. The industrial results showed optimizing catalyst bed level, stripping steam, reaction temperature, equilibrium (e-cat) activity reduced 39%. Other process parameters such as feed preheat slurry recycling, excess oxygen did not significantly influence because maldistribution. Revamping assure symmetrical layout 86%, increased fines retention inventory, provided better regeneration spent e-cat. reduction operating at around 701?C removed risk thermal deactivation, therefore e-cat 10.2 wt.%.