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FCC Webinars

PLAYBACK: 2018 MERTC Presentation: Improving FCC Economics Through Simulation
Presented by Peter Blaser
Vice President Engineering Services, CPFD Software
March 28, 2018

Presenting material shown at the January, 2018, Middle East Refining Technology Conference (MERTC) in Manama, Bahrain. This webinar presents the relationship between simulation and refinery economics, and demonstrates the concepts via industrial case studies from multiple global refiners. Examples shown include regenerator emissions reduction, minimization of regenerator afterburn, reactor and regenerator reliability improvements, catalyst circulation stability assessment, and others.

CLICK HERE to play back this Webinar, or visit our News Item related to this Webinar for more details.

PLAYBACK:
 
2017 ERTC Presentation: Resolving Severe Regenerator
Maldistribution
Presented by Peter Blaser
Vice President Engineering Services, CPFD Software
February 15, 2018

Presenting material shown at the November, 2017, European Refining Technology Conference (ERTC) in Athens, Greece. This webinar will present a case study for an FCC regenerator experiencing severe maldistribution resulting in high afterburn, intermittent catalyst losses and excessive CO and NOx emissions. A team was assembled to evaluate operational and simulation data to evaluate potential regenerator modifications prior to unit shutdown. The decision process and final solution is presented, which resulted in significant emissions reductions and elimination of the intermittent catalyst loss phenomenon. Guidelines are offered to other refiners facing similar issues. The source material for this session was originally presented at the American Fuels and Petrochemical Manufacturer’s 2016 Cat Cracker Seminar.

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PLAYBACK:
Barracuda Virtual Reactor Simulations of PSRI Cold-Flow FCC Stripper Experiment                   
Presented by Sam Clark
Senior Project Engineer, CPFD Software, LLC
December 14, 2017

Presenting material first shown at the 2017 AIChE Annual Meeting, Sam Clark discusses numerical simulations of a PSRI cold-flow FCC stripper experiment with subway grating baffles which were performed using Barracuda Virtual Reactor. Simulation results were compared with experimental measurements found in PSRI's Research Report No. 88 (Issangya et al, 2014) of apparent bed density over a wide range of solids flux conditions at superficial gas velocities typical of industrial FCC stripper operation. The Virtual Reactor™ simulation results were in good agreement with the experimental bed density measurements and matched the experimentally observed trends of bed density variation as a function of gas superficial velocity and catalyst mass flux through the stripper vessel.

CLICK HERE to play back this Webinar, or visit our News Item related to this Webinar for more details.

 

PLAYBACK:
Improving FCC Economics through Computational Particle Fluid Dynamics Simulation                   
Presented by Peter Blaser
Vice President Engineering Services, CPFD Software, LLC
April 20, 2017

Presenting material first published and presented at the 2017 AFPM Annual Meeting, Peter Blaser discusses simulation as a means to "look inside" the FCCU, addressing issues such as erosion, catalyst losses, afterburn, emissions, and catalyst circulation problems by allowing diagnosis of the root cause of issues, testing of the effect of proposed modifications prior to implementation, minimization of the concern of the negative impacts of change, and the pursuit of improved profitability with confidence.

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PLAYBACK:
How Regenerator Maldistribution Affects Emissions, Afterburn and Catalyst Losses
Presented by Ray Fletcher
FCC Senior Technologist, CPFD Software, LLC
September 15, 2016

In its third webinar of its FCC series, CPFD Software discusses a case study set forth in CAT-16-17: The Experience of a Team of Experts to Resolve Severe Regenerator Maldistribution, presented at the AFPM 2016 Cat Cracker Seminar. In this case study, a North American Refiner observed immediate improvements in NOx, CO, and particulate emissions after implementing proposed changes. We discuss how Barracuda VR® was used to analyze potential issues and various solutions, assisting a team of experts in testing and proposing a highly non-intuitive and successful solution to an exceptionally challenging case of maldistribution within the FCC regenerator.

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PLAYBACK: Identifying the Root Cause of Afterburn in FCC Regenerators                   
Presented by Ray Fletcher
FCC Senior Technologist, CPFD Software, LLC
August 12, 2016

In the second webinar in its FCCU simulation series, CPFD Software provides an overview of both stable and unstable forms of afterburn, and shows how Barracuda Virtual Reactor® is used to troubleshoot afterburn issues in FCC regenerators.

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PLAYBACK:
Using Barracuda Virtual Reactor® Simulation to Improve FCCU Process Performance
Presented by Peter Blaser
VP Engineering Services, CPFD Software, LLC
July 13, 2016

In the first webinar in its FCCU simulation series, CPFD Software outlines key processes simulated by Barracuda Virtual Reactor, enabling operators to get a virtual “look inside” their FCCU.

CLICK HERE to play back this Webinar, or visit our News Item related to this Webinar for more details. 

 

 


 

FCC Publications

Modeling FCC spent catalyst regeneration with computational fluid dynamics
aRaj Singh, aEsebius Gbordzoe

aTechnip Stone & Webster Process Technology

Regeneration of spent catalyst is key to the successful operation of the fluid catalytic cracking (FCC) unit. The coke laden spent catalyst from oil cracking in the FCC riser is burned off in the regenerator. The heat generated raises the circulating catalyst temperature and, in turn, helps crack the oil to valuable products in the riser. Efficient regeneration depends on good spent catalyst and combustion air distribution. Ideally, the combustion air is designed to match the spent catalyst distribution.
T
he FCC regenerator has been modeled using various techniques. Technip Stone &Webster Process Technology (Technip) is using computational fluid dynamic (CFD) techniques to develop a tool that simultaneously models both hydrodynamics and coke combustion in the FCC regenerator. Descriptions of the coke burning kinetics are provided through proprietary combustion kinetic equations with appropriate kinetic constants. The results provide detailed qualitativemapping of the regenerator’s behavior in termsof flue gas composition, temperature distribution including afterburning, regenerator bed density in both axial and radial planes. The CFD, coupled with spent catalyst regeneration kinetic model, is used is to evaluate the regenerator performance of a commercial regenerator. The results were used as basis to recommend hardware and operational modifications. The proposed modifications were subsequently modeled using the CFD kinetic tool to quantify the benefits.

Numerical simulation of a commercial FCC regenerator using Multiphase Particle-in-Cell methodology (MP-PIC)
Abdallah S. Berrouk, a,b Allen Huang, Shivkumar Bale, a,c Priyanka Thampi,bKrishnaswamy Nandakumar

aChemical Engineering Dept, Khalifa University of Science and Technology, Petroleum Institute;  b Chemical Engineering Dept, Louisiana State University; c Mechanical Engineering Dept, Herriot Watt University

Catalyst regeneration process has recently been the subject of comprehensive research investigations focusing mainly on the chemistry of the regeneration while overlooking the bed hydrodynamics and its effects on the regeneration performance. For this purpose, an industrial Fluid Catalytic Cracking (FCC) regenerator is simulated using a Multi-Phase Particle-In-Cell (MP-PIC) approach. The simulation is performed using a three-dimensional regenerator design with complex internals in order to study bed hydrodynamics, thermal effects, and chemical kinetics. The numerical model is then used to study typical industrial issues linked to the operation of industrial regenerators such as erosion areas, standpipe drainage, and CO emission levels. It is noticed that total outlet gas flow exceeds total inlet flow due to the formation of coke combustion products, an undersized standpipe, and inefficient placement of the air distributor rings. Highest erosion occurs in the feed line and plate. A low-temperature column exists in the center of the unit, and the highest temperatures are outside of the diplegs in the periphery of the freeboard. Elevated CO levels are present in the outlet gas because of poorly designed air distributor rings and lower than optimal temperatures in the unit. These simulation results show the numerous modeling capabilities of the MP-PIC approach to identify possible performance and reliability issues of an industrial process. Some redesign proposals have been made to enhance the FCC regenerator operations.

Numerical Simulations Of PSRI Cold-Flow FCC Stripper Experiment With Subway Grating Baffles
aSam Clark, bDr. Allan Issangya, bDr. Ray Cocco,aPeter Blaser

aCPFD Software, LLC;  b Particulate Solid Research, Inc.

Numerical simulations of a PSRI cold-flow FCC stripper experiment with subway grating baffles were performed using Barracuda Virtual Reactor. Simulation results were compared with experimental measurements found in PSRI's Research Report No. 88 (Issangya et al, 2014) of apparent bed density over a wide range of solids flux conditions at superficial gas velocities typical of industrial FCC stripper operation. The Virtual Reactor™ simulation results were in good agreement with the experimental bed density measurements and matched the experimentally observed trends of bed density variation as a function of gas superficial velocity and catalyst mass flux through the stripper vessel. 
This paper was originally presented at the 2017 AIChE Annual Meeting, October 29 - November 3, 2017

Improving FCC Economics through Computational Particle Fluid Dynamics Simulation
aPeter Blaser, aRay Fletcher, aSam Clark,

aCPFD Software, LLC

Many FCC units can be operated more profitably, but changes in pursuit of more efficient operation can be risky. Challenges in addressing the root causes of under-performance and fear of unforeseen impacts often result in a strong preference for the status quo. There is a better way. This paper presents simulation as a means to "look inside" the FCCU, allowing the diagnosis of the root cause of issues, testing the effect of proposed modifications prior to implementation, and minimizing the concern of the negative impacts of change, thus enabling the pursuit of improved profitability with confidence.
This paper was originally presented at the 2017 AFPM Annual Meeting, March 19-21, 2017

 

The Experience of a Team of Experts to Resolve Severe Regenerator Maldistribution
aRay Fletcher, aPeter Blaser, aJohn Pendergrass, and bKen Peccatiello

aCPFD Software, LLC;  b Peccatiello Engineering Catalytic Cracking Solutions, LLC

A prominent refinery located in the eastern half of North America recently formed a team of FCC experts with the goal of identifying the root cause and delivering a solution to an exceptionally challenging case of maldistribution within their FCC regenerator. The result was a measurable reduction in the maldistribution resulting in a more stable operation with lower NOx, CO and particulate emissions. This approach may be an excellent model for other refineries facing similar issues within their FCC units.
This paper was originally presented at the American Fuel & Petrochemical Manufacturers' 2016 Cat Cracker Seminar, August 23-24, 2016.

 

Identifying the Root Cause of Afterburn in Fluidized Catalytic Crackers
aRay Fletcher, aSam Clark, aJames Parker, aPeter Blaser

aCPFD Software, LLC

This paper provides an overview of how afterburn presents itself in various operations describing both the stable and unstable forms of general or localized afterburn. 
This work was originally presented at the 2016 AFPM Annual Meeting.

 

Multiphase Simulation Of A Commercial Fluidized Catalytic Cracking Regenerator
aSamuel M. Clark, aDale M. Snider, aRay P. Fletcher

aCPFD Software, LLC

In this paper, a multiphase, thermal, and chemically reacting simulation of a commercial Fluidized Catalytic Cracking (FCC) regenerator was conducted.

 

 


 

FCC Videos

CFD Simulation of an FCC Riser

This video shows the transient, 3D modeling of the thermal and reacting flows inside an FCC riser located on the Arabian Peninsula.

 

Dense-phase Particle Engagement into Dilute-Phase Conveyance

This video shows the transient engagement of densely-loaded spent FCC catalyst exiting from the standpipe into a lift riser for transport into an FCC regenerator. 

 

CO Emissions from an FCC Regenerator

This animation was part of a study conducted by a North American refiner using the Barracuda Virtual Reactor to understand and correct the high levels of carbon monoxide (CO) being produced in their FCC regenerator.

 

Barracuda Virtual Reactor® Validation on FCC Catalyst Fluidization Conducted by PSRI

An experimental unit with gas-solids fluidization of FCC catalysts material performed by PSRI is shown in this video alongside a simulation of the experiment by Barracuda Virtual Reactor.

 

CFD Simulation of a Full-Scale Commercial FCC Regenerator (Full)

A model of a full-scale fluidized catalytic cracking (FCC) regenerator using the Eulerian-Lagrangian CPFD method in Barracuda VR.  This video illustrates the use of the Barracuda Virtual Reactor to predict the 100°F afterburn observed at the refinery.

 

 


 

Recent FCC News Items

March 27, 2018
CPFD Software Attends the 8th World Congress on Particle Technology
 
March 14, 2018
WEBINAR: 2018 MERTC Presentation: Improving FCC Economics Through Simulation
 
January 26, 2018
CPFD Software traveling to Bahrain for MERTC 2018
 
January 16, 2018
WEBINAR: 2017 ERTC Presentation: Resolving Severe Regenerator Maldistribution
 
January 10, 2018
CPFD Software traveling to Malaysia for ARTC 2018
 
December 14, 2017
WEBINAR: Barracuda Virtual Reactor Simulations of PSRI Cold-Flow FCC Stripper Experiment
 
December 12, 2017
CPFD Software Speaking at MERTC 2018 - Bahrain
 
September 10, 2017
European Refining Technology Conference (ERTC) in Greece
 
September 1, 2017
CPFD Software in Minneapolis for the 2017 AIChE Annual Meeting
 
August 16, 2017
2017 AFPM Operations & Process Technology Summit
 
April 6, 2017
WEBINAR: Improving FCC Economics Through Computational Particle Fluid Dynamics Simulation
 
February 15, 2017
CPFD Software To Speak At 2017 AFPM Annual Meeting
 
October 19, 2016
CPFD Software At The 2016 AIChE Annual Meeting
 
August 22, 2016
CPFD Software Announces Technical Advisory Board
 
August 17, 2016
WEBINAR: How Regenerator Maldistribution Affects Emissions, Afterburn And Catalyst Losses
 
July 22, 2016
WEBINAR: Identifying the Root Cause of Afterburn in FCC Regenerators
 
June 23, 2016
WEBINAR: Using Barracuda Virtual Reactor® Simulation To Improve FCCU Process Performance
 
June 10, 2016
CPFD Software Supports AFPM’s 2016 Cat Cracker Seminar
 
February 19, 2016
CPFD Software to Speak At AFPM Annual Meeting
 
February 20, 2015
CPFD Software Supports 5th Annual Joint TRC-JCCP/Idemitsu Workshop