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In this work a simulation of detailed steady state model of an industrial fluid catalytic cracking (FCC) unit with a newly proposed six-lumped kinetic model which cracks gas oil into diesel, gasoline, liquefied petroleum gas (LPG), dry gas and coke. Frequency factors, activation energies and heats of reaction for the catalytic cracking kinetics and a number of model parameters were estimated using a model based parameter estimation technique along with data from an industrial FCC unit in Sudan. The estimated parameters were used to predict the major riser fractions; diesel as 0.1842 kg-lump/kg-feed with a 0.81% error while gasoline as 0.4863 kg-lump/kg-feed with a 2.71% error compared with the plant data. Thus, with good confidence, the developed kinetic model is able to simulate any type of FCC riser with six-lump model as catalyst-to-oil (C/O) ratios were varied and the results predicted the typical riser profiles.

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