Automation and Control of Energy Efficient Fluid Catalytic Cracking Processes for Maximizing Value Added Products

摘要

With an aim to optimize propylene production, petroleum oil is catalytically cracked by contacting the oil with catalyst mixture consisting of a base cracking catalyst containing an stable Y-type zeolite and small amounts of rare-earth metal oxide, and an additive containing a shape-selective zeolite, in an up-flow type fluid catalytic cracking apparatus having a regeneration zone, a separation zone, and a stripping zone. According to this fluid catalytic cracking process, the production of light-fraction olefins such as propylene is maximized by applying appropriate process control, monitoring, and optimizing systems. The present invention provides mathematical process models, including: neural networks, statistical models and finite impulse models. These various mathematical process models are used in conjunction with advanced controllers and optimizing routines to calculate optimal settings for various process parameters. A microwave based system can also be employed for optimizing the performance of a stripping zone, which further optimizes catalyst regeneration. Process model and historical data to test a predictive system can provide early warning of potential performance degradation and equipment failure in the FCC unit, which decreases overall operating costs and increases plant safety.