Process Simulation and Modeling of Fluidized Catalytic Cracker Performance in Crude Refinery

The simulation of fluidized catalytic cracking (FCC) process was performed using Aspen HYSYS. The effect of crude flow rate on naphtha flow, coke yield, and catalyst to oil ratio in FCC were simulated. The interaction effects of riser height, inlet crude flow rate and operating temperature on naphtha mass flow, catalyst to oil ratio, and coke yield were studied by Box-Behnken design. The maximum yield of naphtha (100000 kg/h) was obtained for FCC operating temperature within 520-600 degrees C and riser height greater than 30 m. The catalyst to oil ratio of above 12 was obtained for operating temperature beyond 590 degrees C for the entire riser height variation of 10 to 60 m in FCC. The increase in riser height resulted in increase production of naphtha, but beyond 60 m of riser height secondary cracking occurs resulting in reduction in yield of naphtha.