Dynamic modeling and optimization of an industrial fluid catalytic cracker

Sildir, Hasan; Arkun, Yaman; Canan, Ummuhan; Çelebi, Süleyman; Karani, Utku; Er, Ilay

doi:10.1016/j.jprocont.2015.04.002

Cited by 24 publications

(9 citation statements)

References 45 publications

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“…This coke is the byproduct of the cracking reaction taking place in the riser and get deposited on the catalyst surface in the course of cracking. The intrinsic carbon combustion on the surface of the catalyst corresponds to a couple of reactions producing CO and CO 2 with the second order kinetics [5].…”

Section: The Mathematical Modelmentioning

confidence: 99%

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Modelling and Simulation of Fluid Catalytic Cracking Unit

Ahmed¹,

Ateya²

2016

J Chem Eng Process Technol

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This study presents the dynamic model for an industrial Universal Oil Product (UOP) fluid catalytic cracking unit on basis of mass and energy balance and the transfer functions are found. The riser and regenerator are simulated by using Matlab/Simulink software. The dynamic behaviour of the process is carried out by measuring the temperature response of the riser and regenerator to step change in gas oil flow rate, gas oil temperature, catalyst flow rate, air flow rate and air temperature. The simulator is validated by comparing the steady-state behaviour of the system with those in the literature and plant data and the results are found to be in good agreement. The results of simulation show that the process is strongly influenced by the catalyst flow rate, and any increase in the amount of coke on the catalyst and regenerator temperature would be compensated by a larger rate of consumption of the oxygen.

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Section: The Mathematical Modelmentioning

confidence: 99%

“…Sildir et al [5] developed a dynamic model of the FCC unit which consist of the reactor, the regenerator and the fractionation units. The result showed that a model parameters were estimated from actual industrial data and model predictions match the plant measurements closely.…”

Section: Introductionmentioning

confidence: 99%

Modelling and Simulation of Fluid Catalytic Cracking Unit

Ahmed¹,

Ateya²

2016

J Chem Eng Process Technol

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“…The surge of the computer industry at the end of the 20th century and the use of advanced numerical solvers and new algorithms had a great impact in the area of chemical engineering and led to new PI concepts in the field of process synthesis and design [7]. Different dynamic single-objective optimization (SOO) techniques were available for research on a plant-level [8] and the optimization of processes on a unit-level (e.g., reactor operation) [9][10][11][12][13][14].…”

Section: Dynamic Process Intensification and Forced Periodic Operation Analysismentioning

confidence: 99%

Rapid Multi-Objective Optimization of Periodically Operated Processes Based on the Computer-Aided Nonlinear Frequency Response Method

et al. 2020

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The dynamic optimization of promising forced periodic processes has always been limited by time-consuming and expensive numerical calculations. The Nonlinear Frequency Response (NFR) method removes these limitations by providing excellent estimates of any process performance criteria of interest. Recently, the NFR method evolved to the computer-aided NFR method (cNFR) through a user-friendly software application for the automatic derivation of the functions necessary to estimate process improvement. By combining the cNFR method with standard multi-objective optimization (MOO) techniques, we developed a unique cNFR–MOO methodology for the optimization of periodic operations in the frequency domain. Since the objective functions are defined with entirely algebraic expressions, the dynamic optimization of forced periodic operations is extraordinarily fast. All optimization parameters, i.e., the steady-state point and the forcing parameters (frequency, amplitudes, and phase difference), are determined rapidly in one step. This gives the ability to find an optimal periodic operation around a sub-optimal steady-state point. The cNFR–MOO methodology was applied to two examples and is shown as an efficient and powerful tool for finding the best forced periodic operation. In both examples, the cNFR–MOO methodology gave conditions that could greatly enhance a process that is normally operated in a steady state.

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“…However, some literature studies simplified the model of the regenerator by only developing a model for the regenerator vessel. The model of a regenerator vessel is divided into the dense bed and the dilute phase . The catalyst from the dense bed will recycle to the riser.…”

Section: Process Descriptionmentioning

confidence: 99%

“…6 Similar to the one-layer approach, a two-layer economic MPC structure was proposed to improve the FCCU economic performance in the work of Sildir et al 7 In 2015, Sildir et al proposed a new mathematic model for industrial FCCUs, and some optimization analysis was completed. 8 In 2017, John et al described an industrial FCC model and used gPROMS to maximize the gasoline in the riser. 9 However, as the market's competition becomes fiercer, the refineries pay more attention to the pursuit of economic benefits.…”

Section: ■ Introductionmentioning

confidence: 99%

Enhancing Transient Event Trigger Real-Time Optimization for Fluid Catalytic Cracking Unit Operation with Varying Feedstock

Huang

Zheng

et al. 2019

Ind. Eng. Chem. Res.

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The economic performance of a fluid catalytic cracking unit (FCCU) plays an essential role in the refinery's benefit. A model-based real-time optimization (RTO) is widely applied to improve the unit's economic performance. However, reactions in an FCCU are complex. Also, it is difficult to obtain a model that is the same as the plant's, which leads to an economy loss. What is more, aperiodic perturbations in the feedstock quality make it more difficult to apply the RTO. To further improve the economic performance, an enhancing transient event trigger RTO for FCCU operation was proposed, which integrated the modifier adaptation method and trigger strategy. The modifier adaptation method was adopted to cope with model mismatch. In addition, because of the fast dynamics of a riser, the measures of a riser can partly reflect the steady feature of the whole plant. Hence, the measurements are utilized to calculate the modifiers of the objective function at a high frequency. To avoid useless calculations, a trigger event strategy is also proposed, judging whether the modified optimization problem should be resolved or not. In the simulation results, the proposed scheme was applied to an FCCU model, which was based on a refinery factory in Jiujiang, China. Different situations were demonstrated, and the results verified the efficiency of the proposed scheme.

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Dynamic modeling and optimization of an industrial fluid catalytic cracker

Cited by 24 publications

References 45 publications

Modelling and Simulation of Fluid Catalytic Cracking Unit

Modelling and Simulation of Fluid Catalytic Cracking Unit

Rapid Multi-Objective Optimization of Periodically Operated Processes Based on the Computer-Aided Nonlinear Frequency Response Method

Enhancing Transient Event Trigger Real-Time Optimization for Fluid Catalytic Cracking Unit Operation with Varying Feedstock

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