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Received August 20, 2021
Accepted April 19, 2022
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Study of gradual and sudden operating condition variations to optimize energy and mass consumption of an industrial fluidized catalytic cracking (FCC) unit with a high-efficiency regenerator
Fouman Faculty of Engineering, College of Engineering, University of Tehran, P. O. Box, Fouman 43516-66456, Iran 1Department of Chemical Engineering, University of Guilan, Rasht 41996-13776, Iran 2Refinery Technology Development Department, Research Institute of Petroleum Industry (RIPI), Tehran 1485613111, Iran 3Process Engineering Department, Abadan Refinery, Abadan 6316915651, Iran
n.gilani@guilan.ac.ir, gilani.chem@gmail.com
Korean Journal of Chemical Engineering, July 2022, 39(7), 1673-1687(15), 10.1007/s11814-022-1151-y
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Abstract
A dynamic model was developed to investigate the impact of operating conditions on the main output variables of the fluidized catalytic cracking (FCC) process with a high-efficiency regenerator and to determine the optimal amounts of operating variables, at the Abadan refinery FCC unit in Iran. To determine the rate constants in the developed kinetic model and other related constants in the developed model, a wide range of industrial data were gathered from the targeted process over several months. Through applying an adjusted dynamic model, the effect of gradual increases in feed preheat temperature (350-500 K) on the yield of gasoline and LCO was investigated, and increases in both yields were observed. The effects of sudden changes in feed preheat temperature, feed and regenerated catalyst flow rate on gasoline yield were also examined. The results showed that a sudden 6.9% increase in feed, a sudden 30K decrease in temperature and a sudden 1.12% decrease in catalyst flow rate resulted in 2%, 0.27% and 0.5% decreases in gasoline, respectively. Furthermore, potential methods for neutralizing these negative effects on the gasoline yield were investigated. Finally, the operating conditions were optimized to improve the gasoline and octane number. Three different optimization cases were studied. The profitability of the unit increased about $2.5-3.8 million per year. A reduction in energy consumption of 12,500 to 21,000Gj/yr was achieved. The amount of feed and the catalyst flow rate were also decreased by 1.5% and 0.2%-0.9%, respectively.
Keywords
References
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Pitault I, Forissier M, Bernard JR, Can. J. Chem. Eng., 73, 498 (1995)
Sadighi S, Ahmad A, Rashidzadeh M, Korean J. Chem. Eng., 27, 1099 (2010)
John YM, Mustafa MA, Patel R, Mujtaba IM, Fuel, 235, 1436 (2019)
Sani AG, Ebrahim HA, Azarhoosh M, Fuel, 225, 322 (2018)
Ali H, Rohani S, Chem. Eng. Technol., 20, 118 (1997)
Arbel A, Huang Z, Rinard IH, Shinnar R, Sapre AV, Ind. Eng. Chem. Res., 34, 1228 (1995)
Jacob SM, Gross B, Voltz SE, Weekman VW Jr., AIChE J., 22, 701 (1976)
Secchi A, Santos M, Neumann G, Trierweiler J, Comput. Chem. Eng., 25, 851 (2001)
Kim S, Urm J, Kim DS, Lee K, Lee JM, Korean J. Chem. Eng., 35, 2327 (2018)
Han IS, Chung CB, Chem. Eng. Sci., 56, 1951 (2001)
John YMN, Patel R, Mujtaba IM, Comput. Chem. Eng., 106, 730 (2017)
Takatsuka T, Sato S, Morimoto Y, Hashimoto H, Int. Chem. Eng., 27, 107 (1987)
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Han IS, Riggs JB, Chung CB, Chem. Eng. Process., 43, 1063 (2004)
Hernández-Barajas JR, Vázquez-Román R, Salazar-Sotelo D, Fuel, 85, 849 (2006)
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Jarullah AT, Awad NA, Mujtaba IM, Fuel, 206, 657 (2017)
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Fernandes JL, Verstraete JJ, Pinheiro CI, Oliveira NM, Ribeiro FR, Chem. Eng. Sci., 62, 1184 (2007)
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Alsadik B, Adjustment models in 3D geomatics and computational geophysics: With MATLAB examples, Elsevier (2019).
Pugliese D, Bella F, Cauda V, Lamberti A, Sacco A, Tresso E, Bianco S, ACS Appl. Mater. Interfaces, 5, 11288 (2013)
Galliano S, Bella F, Bonomo M, Giordano F, Grätzel M, Viscardi G, Hagfeldt A, Gerbaldi C, Barolo C, Xanthan‐based hydrogel for stable and efficient quasi‐solid truly aqueous dye‐sensitized solar cell with cobalt mediator, Solar Rrl, 2000823 (2021).
