2023 period data results with technological modifications simulation on a delta basis
Steam consumption normalised to the FCC unit total original design consumption
Simulated (using calibration with 2024 technology)
Modifications 2024 (kg/kg)1
Steam to feed injectors Steam to stripper ring Steam to isolation valve
0.33 0.23 0.05 0.18
Fe ed flow, %
69
Feed density, kg/l
0.917 11.91
Other Total
KUOP
0.78 1 Normalised steam consumption at net design value.
CRC, wt%
0.7 2.9
Vacuum residue in feed, vol%
Table 5
Parameters Reaction temperature, ºC Feed temperature, ºC
515 184 705
Water emissions to SWS unit normalised to the original design conditions
2nd regenerator temperature, ºC CO 2 in first regenerator flue gas, mol%
14.0 CO 2 in second regenerator flue gas, mol% 17.0
Average 2022
Average 2024
(m3/m3)
(m3/m3)
Simulated parameters1
Delta-based values: impact of technology upgrade
Water to SWS
1.77
1.23
Volumetric expansion, vol%2
0.36 5.01 0.95 1.23
Table 6
Conversion, vol%3
Gasoline selectivity, vol%4
Cat/oil, m/m
Test run conditions and results in simulator for both calibration periods
Delta coke, wt%
-0.08
Mass yields Dry gas, wt%
Low conversion
High conversion
-1.64 -0.38 2.76 3.42 -4.52 -0.08 0.38 -0.68 1.33 4.70 -4.95 -0.06
test 102
test 101
C 3 , wt% C 4 , wt%
Feed flow, %1
Feed density, kg/l
0.923 11.88
0.918 11.97
Gasoline, wt%
KUOP
LCO, wt%t SLR, wt% Coke, wt%
CRC, wt%
1.35
1.54 15.9 536 203
Vacuum residue in feed, vol% 10.9
Reaction temperature, ºC2
510 196
Volumetric yields C 3 , vol%
Feed temperature, ºC
Parameters Conversion, vol%
C 4 , vol%
71.3
78.6 75.1
Gasoline, vol%
Selectivity to gasoline, vol% 81.4
LCO, vol% SLR, vol%
Cat/oil, wt/wt
6.6
8.5
Delta coke, wt%
1.08
0.91
1 Delta values referring to the actual values of the 2023 period. 2 Volumetric expansion = (Volume liquid products)/(Volume feed) x100. 3 Conversion =100-(LCO+SLR)_yield. 4 Gasoline selectivity = (Gasoline yield)/Conversion x100.
1 Design throughput percentage basis. 2 The reaction temperature is evaluated as temperature in the stripper zone thermocouple due to modifications in the internals that do not allow the same reaction temperature to be considered.
Table 7
Table 8
v Reduction in main fractionator overhead knockout drum water : The water extracted in the main fractionator overhead knockout drum establishes another evaluation criterion for the vapour reduction of the R2R converter. The average flow obtained in water to the sour water stripper before and after the technological updates establishes this improvement (see Table 6 ). Based on both approaches, an average reduction of 30% in the steam injected into the unit is obtained. Impact of residual feed processing Increasing residual feed processing capacity and its per- formance on unit conversion, as well as the impact on the yields of slurry oil and dry gas, called for an analysis of the effect of technological modifications on unit yields and residual feed processing capacity.
The average value for the period between 09/12 and 17/12 is 0.46 kg/kg. This value is consistent with the data obtained through the empirical correlations, the opac- ity measure, and ash in fuel blend, which verifies the net reduction of particulate emissions of the unit. Reduced MPS consumption The reduction in medium-pressure steam (MPS) consump- tion occurs due to impact injector changes. Its reduction will be evaluated as: u Net reduction of measured and injected steam to the converter : Technological modifications adjust the net steam consumption of the converter according to Table 5 . This results in a 22% net reduction in steam consumption in the FCC.
20
PTQ Q1 2026
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