Catalyst Regeneration, FCC units

The fluid catalytic cracking (FCC) process is an important refinery process in the United States. Catalyst regeneration is an essential part of this process. In the reactor section of a FCC unit, hydrocarbon feed is combined with hot fluidizable cracking catalyst at the base of the riser reactor. Catalyst and hydrocarbon vapors pass up the riser in a dilute-phase, plug-type flow and discharge into the reactor vessel where catalyst and hydrocarbon vapors are separated. When in contact with the catalyst, the hydrocarbon feed cracks to form gasoline, middle distillates, liquefied petroleum gas (LPG), and fuel gas. Coke, which is also formed, deposits on the catalyst surface and greatly reduces the catalyst activity. To restore its activity, the catalyst passes into the regenerator section where the coke is burned off. The heat released from coke burning is completely used to provide the heat requirements on the reactor side. Heat balance, environmental concerns, regenerator configuration and design, and other parameters of FCC are discussed. Keywords: Fluid catalytic cracking (FCC); Catalysts; Heat balance; Coke burning; Emissions; Regenerator; Operating parameters; Catalyst fluidization; Mechanical hardware