This page intentionally left blank

This book is dedicated to our respected clients who have

contributed to the success of RMS Engineering, Inc. and to the content of this book

This page intentionally left blank

Contents

cknowledgments	xi
reface to the Second Edition	xii
HAPTER 1
rocess Description	1

Feed Preheat, 6. Riser—Reactor—Stripper, 7, RegeneratorHeat/Catalyst Recovery, 13. Main Fractionator, 22. Gas Plant, 25. Treating Facilities, 31. Summary, 39. References, 39.

CC Feed Characterization	40
Hydrocarbon Classification, 41. Feedstock Physical	Properties,
45. Impurities, 54. Empirical Correlations, 68. Benefits of
Hydroprocessing, 81. Summary, 82. References, 82.
HAPTER 3
CC Catalysts	84

Catalyst Components, 84. Catalyst Manufacturing Techniques, 96. Fresh Catalyst Properties, 99. Equilibrium Catalyst Analysis, 102. Catalyst Management, 109. Catalyst Evaluation. 115. Additives, 117. Summary, 123. References, 124.

HAPTER 4
hemistry of FCC Reactions	125

Thermal Cracking, 126. Catalytic Cracking, 128. Thermodynamic Aspects, 136. Summary, 136. References, 138 References, 134.

HAPTER 5
nit Monitoring and Control	_.._ 139

Material Balance, 140. Heat Balance, 158. Pressure Balance, 166. Process Control Instrumentation, 177. Summary, 180. References, 181.

HAPTER 6

roducts and Economics	182
FCC Products, 182. FCC Economics, 202. Summary, 205.
References, 205.
HAPTER 7
roject Management and	206
ardware Design
Project Management Aspects of an FCC Revamp, 206.
Process and Mechanical Design Guidelines, 212.
Summary, 232. References,	232.
HAPTER 8
roubleshooting	234

Guidelines for Effective Troubleshooting, 235. Catalyst Circulation, 236. Catalyst Losses, 244. Coking/Fouling, 248. Flow Reversal, 251. High Regenerator Temperature, 256.

Increase in Afterburn, 259. Hydrogen Blistering, 260.		Hot
Gas Expanders, 263. Product Quantity and Quality, 264.
Summary, 275.
HAPTER 9
ebottlenecking and Optimization		276
Introduction, 276. Approach to Debottlenecking, 277.
Reactor/Regenerator	Structure, 281. Flue Gas System,	296.
FCC Catalyst, 296.	Instrumentation, 304. Utilities/Offsites,
305. Summary, 306.

merging Trends in Fluidized Catalytic Cracking _

307

Reformulated Fuels, 308. Residual Fluidized Catalytic Cracking (RFCC), 323. Reducing FCC Emissions, 327. Emerging Developments in Catalysts, Processes, and Hardware, 232. Summary, 335. References, 336.

PPENDIX 1
emperature Variation of Liquid Viscosity		338
PPENDIX 2
orrection to Volumetric Average Boiling	Point	339
PPENDIX 3
OTAL Correlations		340
PPENDIX 4
-d-M Correlations _.._._ ._.._ __._	_	341
PPENDIX 5
stimation of Molecular Weight of		342
etroleum Oils from Viscosity Measurements
PPENDIX 6
inematic Viscosity to	_	344
aybolt Universal Viscosity _._
PPENDIX 7
PI Correlations		345

PPENDIX 8
efinitions of Fluidization Terms	_._..._..._ _	347

onversion	of ASTM 50%	Point		_	350
TBP 50% Point Temperature
PPENDIX 10
etermination of TBP Cut					351
oints from ASTM D-86
PPENDIX 11
ominal Pipe Sizes			__._	_	353
onversion	Factors __	_		..._...	355
lossary			....._.		357
dex	_._ _				363
bout the Author			..__ _	._	.__. 369