Steady State Analysis of a UOP SBS Fluid Catalytic Cracking Unit in Aspen HYSYS

This research paper offers a comprehensive study of the steady-state simulation of a Fluid Catalytic Cracking Unit (FCCU). By utilizing Aspen HYSYS as the simulation platform, we conducted a methodical examination of how critical input parameters affected the performance of the unit in both open-loop and closed-loop scenarios. The impact of catalyst circulation rate (FC) and regenerator inlet air flow rate (FA) on conversion, product yields, and other critical output parameters was investigated in open-loop operation. Remarkably, it was observed that the reactor section had a profound impact on the regenerator, while the reverse relationship was not as pronounced. Closed-loop performance assessment revealed the necessity of adjusting feed oil temperature and oxygen concentration in the flue gas to restore Naphtha yield when deviations occur. Notably, variations in feed flow rate had a direct effect on conversion and Naphtha yield, with adjustments in feed oil inlet temperature (TA) or oxygen concentration offering avenues for restoration. Furthermore, this research emphasizes the unidirectional relationship between the regenerator and reactor sections, in which the efficacy of the reactor has a substantial impact on the regenerator. These findings provide valuable insights for optimizing the operation of FCCUs and developing effective control strategies to enhance Naphtha yield while maintaining process stability.