FCC Catalyst Allocation Modeling for Flushing Quality Variations
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Solution Overview
Problem
Current fluid catalytic cracking (FCC) process simulators have low adherence to predicting the performance of FCC units with variations in flushing catalyst content and quality, particularly when integrating conventional and residue FCC units, leading to inefficiencies in catalyst allocation and increased logistical costs.
Innovation Solution
An integrated operation method that uses a model to predict catalytic performance and optimize the allocation of virgin and flushing catalysts between conventional and residue FCC units, incorporating process simulators like SimCraqOT, FCC-SIM™, or Hysys, to improve adherence and logistical efficiency by quantifying and classifying flushing catalysts based on quality and content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If process simulators are used to predict FCC unit performance with variations in flushing catalyst content and quality, then catalyst allocation can be optimized, but the predictive accuracy and adherence of the models remain low
Solution Approach 1:
The patent modifies process simulator parameters to incorporate flushing catalyst characteristics (content and quality variations) into the predictive models. By changing the parameters to account for catalyst composition, metal content, and activity levels, the model achieves better predictive accuracy while maintaining reliability across different operating conditions
Solution Approach 2:
The patent applies preliminary calibration and validation actions to the process simulator models before use. By pre-adjusting the models with historical data and establishing baseline performance characteristics, the system ensures high predictive accuracy and model adherence is achieved before actual catalyst allocation optimization begins
2Object-affected harmful factors
If flushing catalyst is used to reduce contaminating metals in residue FCC units, then metal accumulation is mitigated, but catalyst replacement costs and logistical complexity increase
Solution Approach 1:
The patent introduces an integrated operation system as an intermediary that coordinates flushing catalyst distribution across multiple FCC units. This system optimizes which units receive flushing catalyst based on their specific metal accumulation rates and processing conditions, reducing overall logistical complexity while effectively mitigating metal accumulation
Solution Approach 2:
The patent creates a multi-functional catalyst management system that handles both conventional and residue FCC units through a single integrated approach. The system universally applies catalyst allocation strategies across different unit types, reducing logistical complexity by eliminating separate management procedures while still addressing metal accumulation in each unit type
3Productivity
If integrated operation method is implemented to optimize catalyst allocation, then operational efficiency improves, but implementation complexity and model modification requirements increase
Solution Approach 1:
The patent merges the process simulator models with the production planning model into an integrated operation system. By combining these previously separate systems, the patent achieves improved operational efficiency through coordinated catalyst allocation while managing implementation complexity through a unified rather than multiple separate implementations
Data Source
AI summary
The present invention refers to an integrated operation method of conventional and residue FCC units that applies a model developed for predicting the catalytic performance of residue FCC units with any content and quality of flushing for the correct prediction and optimization of process simulators for residue FCC units and refining production planning models. The application can be for individual studies in process simulators or in digital twins to mitigate the unreliability in the prediction of the original simulator for studies with wide alteration in the content and quality of the flushing. The other application consists of modifying the refining production planning models based on the simulation result obtained in the modified process simulators to predict the performance of the waste units operating for any variation in the content and quality of the flushing catalyst used. The refining production planning model allows: 1. Indicative of potential profitability gain; 2. Optimum replacement of virgin and flushing catalysts in the conventional and residue FCC units; 3. Better distribution of the flushing content and flushing quality for FCC consumer units of the flushing system; 4. Quantifies the marginal value of flushing generated in the FCCs units that produce flushing; 5. Defines the best virgin catalyst budget and predicts the logistical costs of transporting flushing between the FCC units producing flushing and consuming flushing, considering all viable routes.