Reduce catalyst loss within the system
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During the normal operation of a catalytic cracking unit, what measures can be taken to reduce catalyst loss within the system? It seems that there is significant catalyst consumption on our unit during heavy oil catalysis; when the specific catalyst consumption falls below 0.7 kg/t, the system’s catalyst inventory tends to decrease.
Our design value here is 0.6 kg/t
Is 0.6kg/t a loss?
So, where is the catalyst being lost from? What’s the solid content in the oil slurry? How much catalyst is recovered through the four-stage cyclone system? Only by analyzing whether the loss occurs in the regenerator or the settler can we take appropriate measures to investigate the issue
The solid content of the slurry is 3–4 g/l; it seems that the losses in the settler are not significant, while the losses are likely to be greater on the side of the regenerator. What measures can be taken to optimize things and reduce these losses?
1. Catalyst carryover in the regeneration system is mostly influenced by factors such as an increase in the distribution of fine catalyst particles, a rise in the amount of catalyst inventory, and an increase in the gas velocity at the cyclone inlet. 2. If there are problems with the cyclone separation system (including issues related to dipleg balance), the tendency for catalyst carryover persists and gradually worsens rather than abating. 3. Regeneration temperature and pressure indirectly affect the state and flow rate of the gas; ultimately, these effects are reflected in the gas velocity at the cyclone inlet
Calculate the catalyst balance to determine where the catalyst goes, and use that information to identify which part is having problems. You can't simply suspect the cyclone separator in your current situation