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Presentation at Ecopetrol
October 2008
CONFIDENTIAL 1
Why FCC Troubleshooting is Complex
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Attack the Problem Systematically
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Potential Reasons For Increased
Catalyst Losses
# 3 = Operational changes
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Typical 2-Stage Cyclone System
Plenum
Gas Outlet Tube
2nd Barrel
Gas Inlet Duct Stage
1st
Stage
Dust Hopper
Cone
Dipleg
Flapper Valve
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#1. Cyclone or Mechanical Damage -
Holes in Cyclone or Plenum
Operational effects Catalyst effects
increased attrition of
fresh catalyst
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#2. Change in Catalyst / Attrition
Increase in cyclone
pressure drop
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#3. Operational Changes -
Increased Catalyst Entrainment
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#3. Operational Changes -
Reactor-side Coking
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Symptoms of Catalyst Circulation
Problems
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Potential Reasons For Circulation
Constraints
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Typical FCC Aeration Layout
REGENERATOR
STRIPPER
RISER
FEED
STEAM
STEAM STEAM
STEAM
AIR
STEAM
AIR
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#1. Poor Standpipe Aeration
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#2. Catalyst Particle Size (Too
Course)
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#3. FCC Mechanical Issues -
Cyclone Problems
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#3. FCC Mechanical Issues -
Refractory Obstructing Slide Valve
Operational /
mechanical effects Catalyst effects
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#3. FCC Mechanical Issues -
Air Grid Pluggage
Operational /
Catalyst effects
mechanical effects
High grid P
Low grid P
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Conclusions