GET INDUCTION PROGRAMME

ADSORPTION ABSORPTION CRACKING

ADSORPTION
Preferential partitioning of substances from the gaseous or liquid phase onto the surface of a solid substrate is Called Adsorption Distillation : Relative volatility Absorption: Solubility Extraction: Distribution Coefficient Adsorption: Pore diameter Examples of Uses of Adsorption: a. Removal of CO, CO2, CH4 from Hydrogen in PSA Unit b. Use of desiccant to prevent corrosion in spares transportation

Adsorbents Desirable Properties

Adsorption - Surface Phenomenon -van der Waals forces and electrostatic forces between adsorbate molecules and the atoms which compose the adsorbent surface. Thus adsorbents are characterized first by surface properties such as surface area and polarity.

Should have large internal surface area Adsorbent should be regenerable Should not age easily

Pore size

Mechanical Strength

Absorption

The process of removal of one or more selected components from a mixture of gases into suitable liquid by interphase mass transfer controlled largely by rate of diffusion.

Absorption - type
Absorption - Physical
Example : Absorption of H2S in water Depends upon solubility of solutes to be removed in liquid No chemical reaction Little heat released

Absorption - Accompanied by Chemical Reaction

Absorption of H2S in MDEA
(CH2OHCH2)2NCH3 +H2S (CH2OHCH2)2NSCH3 Depends on chemical reaction of solute with liquid

Significant heat release

Equipment
Plate Tower
Type of Trays Downcomer

Distributor pipe

Packed Tower
Packing support plate Packing Redistribution of liquid

Cracking
Cracking is the process of decomposition of high molecular weight hydrocarbons to more valuable lower molecular weight hydrocarbon.

Types :

a.

Thermal
Fixed bed Moving Bed FCC

b.

Catalytic

Thermal Cracking
Thermal Cracking is defined as the thermal decomposition, under pressure, of large hydrocarbon molecules to form smaller molecules Large Molecules decompose into smaller : C10H22 C8H17 + C2H5 C2H5 + C6H14 C2H6 + C6H13 Free radicals react with other molecules to form sat HC & FR. C6H13 C5H10 + CH3 C8H17 C4H8 + C4H9 C4H9 C4H8 + H Termination of chain reaction :
CH3 + H CH4

Thermal Cracking
PC PC TC

Sour Water
Thermal Cracked Naphtha

Surge Drum PC

Long Residue
FC TC FC

TC

Thermal Residue

Vacuum Flasher

Fuel

Steam Visbreaking Residue

Thermal Cracking -Salient Features

Design of all equipment is to minimize coke formation Heaters : tube diameter, Charge stock velocities, Heating rate Temperature, Metallurgy, Coke prevention, Zone temperature control. Gas oil stream is frequently used to wet the walls of soak drum to prevent coke accumulation. Use of stand by drum.

Soak Drum

Pumps

Should be able to handle high temp, corrosive liq.

Fixed Bed Catalytic Cracking

Wet Gas to Stabilizer

Light CGO

Motor Gasoline to Stabilizer

Charge Heater
Spent Air

Heavy Catalyti Gas Oil Fresh Air

Heat Exchanger Air Heater

Turbo Compressor

Moving Bed Catalytic Cracking

Lift Disengaging Hopper

Flue Gas
Reactor Product

Purge Steam

Elutriator

Steam Steam
BFW

Kiln

Lift Engaging Hopper

Fresh Catalyst Storage

Reactor

Fluidized bed Catalytic Cracking

Objective : To convert heavy fuel components into high-octane motor gasoline blending components.

By products: Coke, C4 feed. Interface with other Units: Overhead gas Gasoline Bottoms

Process Description
Health, Safety, Environment & Fire (HSEF)

FCC - Process Flow

FLUIDIZED CATALYTIC CRACKING UNIT
1.55 Kg/cm2g 546 oC
Rx Vapors

Primary Absorber

Sponge Absorber

Amine Absorber
Treated Gas to FG System

121 oC
Reflux Drum

MC ovhd vapor

Main Column
Flue Gas to PRT 1

Receiver

Lean Oil

Reactor
10

Compressor HP Receiver
HP Liquid to Stripper Rich Oil Rich Amine to ATU Lean Amine fr ATU

2.34 Kg/cm2g Regenerator 714 oC

1 26

Stripper
1

Heavy Naphtha Stripper

MP Steam

MC ovhd liquid

Regenerated Catalyst

Light Cycle Oil Stripper

Stripper

Debutanizer

Naphtha Splitter

Depentanizer

Combustor
Spent Catalyst
Fuel Gas

Riser

6 MP Steam 42

Deisohexanizer
LPG to Merox C5 to SHP / LNUU i-C6 to Light Mogas header Heavy Naphtha (155-215C) to Reactor Heavy cracked Naphtha Product (180-215 C)/ Heavy Mogas header Light Cycle Oil Product to Diesel Blending System Fuel Oil Product to FO System C6-105 Naph. to LNUU / Light Mogas header C5-105 Naph. to LNUU / Merox 155-180 Naph to Reactor 105-180 Naph to HNUU / Heavy Mogas header C6-105 Naph. to LNUU

Raw oil

Process Air

Stack Orifice Chamber Flue Gas Cooler

C7-105 Naph. to Riser

3rd stg sep. 4th stg. sep. Expander

HP Steam

BFW Air

Main Air Blower

Steam Turbine

Motor/ Generator

Process Air to Rg To Recovered Cat. Hopper

Hydrocracker
Objective : To convert fuel oil components into Naphtha, Kerosene, and gas oil Feed Stock Hydrogen comes from HMU LPG Naphtha Kerosene

Interface with other Units:

Process Description HSEF

Hydrocracker - Process Flow

TC

High Pressor Separator Fractionation

PC

Fist Stage Reactorr

Second Stage Reactorr