Evaluating the Optimal Capacity for the Implementation of Fluidized Catalytic Cracking in the Refinery by the Technical and Economic Analysis

Fluidized catalytic cracking (FCC) unit has vital role in the process of modern refineries because this unit is used for production of valuable refinery products. The aim of this research is to study different capacities of the feedstock in FCC unit and to find the maximum available capacity with consideration of technical and economic criteria. In this regard, process simulation of this unit is performed in the Aspen HYSYS software. Next, this process simulation is imported to Aspen Capital Cost Estimator (or ICARUS) for operating cost (OPEX) and capital cost (CAPEX) evaluations. Finally, it is tried to optimize the capacity of fluidized bed catalytic cracking process. By investigating the results, it was revealed that the breakeven point (BEP) in this unit is in the capacity of 30 000 barrels per day. It means that total cost (operating and capital costs) and net profit (revenue of products) are equal and at the higher capacities than this BEP, FCC unit has profitability. Based on the economic analysis, it could be found that CAPEX and OPEX in the BEP capacity will be more than 156 618 948 $ and 37 432 199 $/yr, respectively.

Automated summary

The study aims to explore different feedstock capacities in the FCC unit and identify the maximum usable capacity based on technical and economic criteria. Through process simulation and economic analysis, it was found that the breakeven point is at a capacity of 30,000 barrels per day, beyond which the FCC unit becomes profitable.