So tay van hanh U-15

7/27/2019 So tay van hanh U-15

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QUY TRNH VN HNH

PHN XNG RFCC8474L-015-ML-001-0RFCC Group

9/5/2008

Ti liu ny l s tay vn hnh ca phn xng RFCC (phn xng 15) ca d n nh mylc du Dung Qut thuc Tp on du kh Vit Nam


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Table of Contents

Table of Contents.......................................................................................................................................ii

1. C s thit k........................................................................................................................................ ix

1.1 Gii thiu v mc ch ca d n......................................................................................ix

1.2 C s thit k.................................................................................................................... xi

1.2.1 Mc ch v cng sut ca phn xng.....................................................................................xi1.2.2 Tnh cht nguyn liu............................................................................................................... xii1.2.3 Tnh cht sn phm.................................................................................................................. xiv1.2.4 Thng s vn hnh ..................................................................................................................xix1.2.5 Cc iu kin trong ranh gii phn xng.............................................................................xxii

1.2.6 iu kin vn hnh v thit k ca cc dng ph tr............................................................xxiii1.3 Cn bng vt cht..........................................................................................................xxiv

1.3.1 Thp phn ng-thp ti sinh-x l xc tc v x l kh thi...................................................xxiv1.4 L thuyt cng ngh......................................................................................................xxvii

1.4.1 Cc phn ng ha hc v xc tc..................................................................................... ....xxvii1.4.2 Cc loi phn ng................................................................................................................xxviii1.4.3 Cc phn ng mong mun.................................................................................................... xxxii1.4.4 Cc phn ng cn c gii hn (nhng khng loi b).....................................................xxxiii1.4.5 Cc phn ng khng mong mun cn c gim thiu........................................................xxxiv1.4.6 Kh nng la chn chuyn ho ca cc h hyrccbon khc nhau....................................xxxiv1.4.7 Xc tc............................................................................................................................. ...xxxvii1.4.8 Qu trnh ti sinh xc tc....................................................................................................... xliii

2 M t phn xng................................................................................................................................xlv

2.1 Cm phn ng ti sinh bo qun xc tc x l khi thi.........................................xlv

2.1.1 H phn ng...................................................................................................................... ......xlv2.1.2 H thng ti sinh...................................................................................................................xlviii

2.2 Nhng nt c trng ca cng ngh. ...............................................................................lii

2.2.1 Thit k cold wall :.................................................................................................................... lii2.2.2 H thng phun nguyn liu........................................................................................................lii

2.2.3 H thng MTC (Ch p dng cho trng hp Max Gasoline i vi du Mixed).....................liv2.2.4 H thng tch xc tc ti u ra ca Riser................................................................................lv2.2.5 Qu trnh ti sinh hai cp..........................................................................................................lv2.2.6 Cc van c bit....................................................................................................................... lvi2.2.7 Vng hi nc v tr y ca riser.........................................................................................lvi2.2.8 Cc h thng Aeration v fluidization.....................................................................................lvii2.2.9 Vng hi nc y Stripper ................................................................................................lviii2.2.10 Fluffing ring trong thit b ti sinh th nht.........................................................................lviii

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2.2.11 Vng kh trong ng rt xc tc ti sinh withdrawal well. ...............................................lviii2.2.12 Cc vng khng kh cho qu trnh t chy cc. .................................................................lviii

2.3 Xc tc.............................................................................................................................. lix

2.4 X l flue gas. .................................................................................................................. lxi

2.5 Cm chun b nguyn liu v cm chng ct...................................................................lxi

2.5.1 Feed section..............................................................................................................................lxi2.5.2 Nguyn liu Mixed crude......................................................................................................... lxii2.5.3 Khu vc y ca thp chng ct chnh. ..................................................................................lxii2.5.4 HCO section...........................................................................................................................lxiii2.5.5 LCO section............................................................................................................................ lxiv2.5.6 Khu vc MTC v heavy naphtha.............................................................................................lxiv2.5.7 Khu vc nh thp.................................................................................................................... lxv2.5.8 Khu vc nh thp.................................................................................................................... lxv

2.6. Cm thu hi kh.............................................................................................................. lxvi

2.6.1. Wet gas compressor v HP condenser...................................................................................lxvi2.6.2. Stripper condenser v Bnh tch cao p................................................................................lxvi2.6.3. Primary absorber..................................................................................................................lxvii2.6.4. Stripper................................................................................................................................. lxvii2.6.5. Secondary absorber.............................................................................................................. lxvii2.6.6. Fuel gas absorber................................................................................................................lxviii2.6.7. Debutanizer...................................................................................................................... ... lxviii2.6.8. LPG amine absorber..............................................................................................................lxix

3. M t qu trnh iu khin ca phn xng.................................................................................... lxx

3.1. Nguyn l iu khin ca qu trnh cng ngh...............................................................lxx

3.2. Thng s cng ngh ca cm reactor v regeneration.................................................. lxxii3.2.1. Tng qut.............................................................................................................................. lxxii3.2.2. Nhit u ra ca Riser....................................................................................................lxxiii3.2.3. p sut ca Disengager....................................................................................................... lxxiv3.2.4. Hot tnh ca xc tc.......................................................................................................... .lxxiv3.2.5. Cn bng kh ca Regenerators............................................................................................ lxxv3.2.6. Nhit ca thp ti sinh......................................................................................... ........... lxxvi3.2.7. Thi gian lu trong thp ti sinh..........................................................................................lxxvi3.2.8. Tc trong thp ti sinh................................................................................................... lxxvii3.2.9. Vn hnh stripper............................................................................................................... lxxvii

3.2.10. Cn bng nhit.................................................................................................................. lxxvii3.2.11. Cht lng nguyn liu:.....................................................................................................lxxix3.2.12. Nhit dng nguyn liu...................................................................................................lxxx3.2.13. Sn lng cc, delta cc, t l xc tc/du..........................................................................lxxx3.2.14. Cn bng p, tun hon xc tc........................................................................................lxxxii

3.3. Cc thng s cng ngh.............................................................................................. lxxxii

3.3.1. Gii thiu............................................................................................................................ lxxxii3.3.2. Cc bin phn ng ca RFCC........................................................................................... lxxxiii

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3.3.3. nh hng ca nhit nguyn liu..................................................................................lxxxiv3.3.4. nh hng ca nhit u ra Riser ................................................................................lxxxvi3.3.5. nh hng ca thi gian lu............................................................................................lxxxviii3.3.6. nh hng ca hot tnh xc tc........................................................................................lxxxix3.3.7. nh hng ca lu lng dng tun hon...............................................................................xc

3.3.8. nh hng ca cht lng nguyn liu...................................................................................xci3.3.9. nh hng ca kim loi v cn carbon..................................................................................xcii

3.4. Ngun cp in d phng (UPS)...................................................................................xcii

4. Ha cht, Xc tc v Ph tr.......................................................................................................... ..xcv

4.1 c tnh xc tc..............................................................................................................xcv

4.1.1 S lng xc tc tc np thm............................................................................................xcv4.1.2 La chn xc tc..................................................................................................................... xcv

4.2 Antimony (Nickel passivator, ch dng cho Mixed Crude Case).....................................xcv

4.3 Cht c ch n mn....................................................................................................... xcvi

4.4 Tc nhn chng to bt..................................................................................................xcvi4.5 Amine (outside battery limit)..........................................................................................xcvi

4.6 Phosphate cung cp cho h thong thit b sn xut hi nc........................................xcvi

4.7 c tnh tiu th ph tr............................................................................................... xcvii

5. Chun b cho qu trnh khi ng ln u...................................................................................xcviii

5.1 Trnh t vn hnh....................................................................................................... xcviii

5.2 Kim tra phn xng v thit b....................................................................................xcix

5.2.1 Kim tra thit b..................................................................................................................... xcix

5.2.2 Kim tra phn xng................................................................................................................ci5.2.3 Line Flushing Outline............................................................................................................... cv5.2.4 Chy thit b quay...................................................................................................................cvi

5.3 Preliminary operation......................................................................................................cviii

5.3.1 nh ngha.............................................................................................................................cviii5.3.2 Commissioning h thng ph tr...........................................................................................cviii5.3.3 Commissioning phn xng.....................................................................................................cix5.3.4 Kim tra r r ban u.............................................................................................................. cx5.3.5 Qu trnh np xc tc vo cc hopper.....................................................................................cxi5.3.5.1 Kim tra s b.......................................................................................................................cxi

5.3.5.2 Khuyn co........................................................................................................................... cxi5.4 Khi ng ln u............................................................................................................cxi

5.4.1 Tng qut................................................................................................................................. cxi5.4.2 Tnh trng phn xng......................................................................................................... ..cxii5.4.3 Th t nhng thao tc vn hnh trong qu trnh khi ng...................................................cxii5.4.4 Khi ng v kim tra Blower...............................................................................................cxiii5.4.5 Dry-out lp refractory ...........................................................................................................cxvi

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5.4.6 Kim tra lp refractory ........................................................................................................cxxii5.4.7 Dry-out v un si bay hi ha cht trong CO Boiler/ Waste Heat Boiler...........................cxxii5.4.8 un si soda ca dng BFW ca WHB................................................................................cxxiii5.4.9 un si soda ca thit b sn xut hi nc cm y thp Main Fractionator.................cxxiii5.4.10 X l nhn trong h thng dng Amine..............................................................................cxxiii

6. Khi ng ln u v khi ng thng thng............................................................................cxxiv6.1 Tm tt qu trnh khi ng.........................................................................................cxxiv

6.1.1 Cm phn ng v ti sinh:........................................................................................... ........cxxiv6.1.2 Cm phn tch chnh v Thu hi kh:...................................................................................cxxix

6.2 Cc bc chun b cui cng.....................................................................................cxxxiii

6.2.1 Kim tra li cc bc chun b:.........................................................................................cxxxiii6.2.2 Chun b ca cc phn xng lin quan v cc phn xng Off site:.................................cxxxv

6.3 Qui trnh khi ng cm phn ng v cm ti sinh:...................................................cxxxvi

6.3.1 Giai on lm nng cm phn ng:......................................................................... ..........cxxxvi

6.3.2 M van MOV-001 ti thit b phn tch chnh:................................................................cxxxviii6.3.3 Np xc tc........................................................................................................................cxxxix6.3.4 Tun hon xc tc..................................................................................................................cxlii6.3.5 Np nguyn liu vo Riser....................................................................................................cxliii6.3.6 Commissioning h thng MTC..............................................................................................cxlvi

6.4 Khi ng cm chng ct ............................................................................................cxlvi

6.4.1 Mc ch............................................................................................................................... cxlvi6.4.2 Tnh trng ca phn xng...................................................................................................cxlvi6.4.3 Steam-out (hay thi bng nitrogen)......................................................................................cxlvii6.4.5 Tun hon ngui cho cm thu hi kh.......................................................................................cli6.4.6 Tun hon nng cho Thp chng ct chnh .............................................................................cli6.4.8 Khi ng my nn kh...........................................................................................................cliii6.4.9 Quy trnh khi ng my nn kh............................................................................................cliii6.4.10 To p cm thu hi kh v tun hon xng nh.....................................................................cliv6.4.11 Gia nhit cm stripper v debutanizer...................................................................................clv6.4.12 Np liu................................................................................................................................ clvi

7. iu kin vn hnh bnh thng ca phn xng..................................................................... .....clix

7.1 Bng tm tt iu kin vn hnh.....................................................................................clix

7.2 Nguyn l iu khin........................................................................................................clx

7.3 Cc thng s vn hnh..................................................................................................clxiii

7.3.1 Cng sut..............................................................................................................................clxiii7.3.2 Nhit u ra riser.............................................................................................................clxiii7.3.3 p sut vng phn tch (disengager)....................................................................................clxiv7.3.4 Hot tnh xc tc...................................................................................................................clxiv7.3.5 Cn bng khng kh trong cc thp ti sinh...........................................................................clxv7.3.6 Nhit ti sinh....................................................................................................................clxvi7.3.7 Thi gian lu trong thp ti sinh...........................................................................................clxvi

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7.3.8 Tc kh trong thp ti sinh..............................................................................................clxvii7.3.9 Qu trnh lm vic ca stripper.......................................................................................... .clxvii7.3.10 Cn bng nhit...................................................................................................................clxvii7.3.11 Cht lng nguyn liu.......................................................................................................clxix7.3.12 Nhit nguyn liu.............................................................................................................clxx

7.3.13 Sn lng cc / delta cc / t l xc tc/du........................................................................clxxi7.3.14 Qu trnh tun hon xc tc/cn bng p..........................................................................clxxii

7.4 iu chnh cc iu kin vn hnh..............................................................................clxxiii

7.4.1 Tnh cht nguyn liu..........................................................................................................clxxiv7.4.2 Cn bng khi..................................................................................................................... clxxiv7.4.3 Tnh cht sn phm.............................................................................................................clxxiv7.4.4 Cn bng nhit..................................................................................................................... clxxv7.4.5 Cn bng p sut ................................................................................................................clxxxi

7.5 Catalyst management................................................................................................clxxxiv

7.5.1 Phn tch xc tc...............................................................................................................clxxxiv

7.5.2 Thay th xc tc.................................................................................................................clxxxix7.5.3 B sung xc tc. ................................................................................................................clxxxix7.5.4 Rt xc tc ..............................................................................................................................cxc

7.6 Vn hnh trong phn thp tch chnh v thu hi kh. ....................................................cxcii

7.6.1 Phn thp tch chnh............................................................................................................ cxcii7.6.2. Cm thu hi kh ................................................................................................................. cxcvii

7.7. Vn hnh ph tr (supporting facility operation).............................................................cc

7.7.1. Vn hnh blow-down ca thit b sinh hi...............................................................................cc7.7.2. Hot ng ca thit b tch slurry............................................................................................cc7.7.3. Nhng im lu khi vn hnh bm slurry............................................................................cci

7.7.4. Quan st n mn................................................................................................................ cci7.7.5. H thng cung cp kh pilot v fuel gas.................................................................................ccii7.7.6. X l slop oil..........................................................................................................................ccii7.7.7. Vn hnh dng minimum ca bm........................................................................................cciii7.7.8. Vn hnh thit b phn tch trn dng flue gas.....................................................................cciii

7.8. Troubleshooting............................................................................................................cciv

7.8.1. Nhng tnh hung troubleshooting........................................................................................cciv7.8.2. Cc vn tun hon xc tc................................................................................................cciv7.8.3. Tht thot ln xc tc.............................................................................................................ccv7.8.4. Cht lng khng tt ca qu trnh ti sinh..........................................................................ccvi

7.8.5. Spent catalyst stripping........................................................................................................ccvii7.8.6. Cht lng v s lng ca sn phm.................................................................................ccvii7.8.7. Shutdown mt phn ca Electrostatic Precipitator.............................................................ccviii

7.9. Cc lu vn hnh, relating hazop follow-up action.....................................................ccix

7.9.1. Li ca h thng cung cp hi nc nguyn t ha nguyn liu......................................ccix7.9.2. B lc tm thi ti u cui ca dng nguyn liu M-1501..................................................ccix7.9.3. Vn hnh MOV-001 v valve cch ly PSV-002.....................................................................ccix

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7.9.4. Trnh hin tng ng c ca nguyn liu..........................................................................ccx7.9.5. iu khin nhit reactor cho vic hnh thnh coke............................................................ccx7.9.6. Nguyn t ha dng MTC................................................................................................... ..ccxi7.9.7. Trnh hin tng to chn khng trong thit b phn ng....................................................ccxi7.9.8. in cht th ng kim loi vo bnh D-1508.......................................................................ccxi

7.9.9. Cc lu khi a b o chnh p PDT-103 ca slide van SV-1502 vo hot ng..............ccxi7.9.10. Phng php ly mu xc tc............................................................................................ccxii7.9.11. Vn hnh cc cc variable orifice trn dng khi thi ra khi thit b ti sinh..................ccxii7.9.12. iu khin lng khng kh t chy vo thit b ti sinh th nht..................................ccxiii7.9.13. iu chnh lng khng kh vo tng ti sinh th hai.......................................................ccxiii7.9.14. Nhit dng khi thi ti u ra Economizer.................................................................ccxiii7.9.15. Thi ra cc thit b trao i nhit lm vic vi slurry khi cc thit b ny khng hot ng....................................................................................................................................................... ccxiv7.9.16. Chuyn E-1506A/B t ch stand-by sang vn hnh.....................................................ccxiv7.9.17. Gia nhit nc l hi cao p HP-BFW bng E-1516 v E-1511........................................ccxv7.9.18. Vn hnh bm ca bnh tch lng trc khi vo u ht ca WGC...................................ccxv

7.9.19. Gim p thit b hp th LPG bng amine.........................................................................ccxv7.9.20. Nhit tng ti sinh th nht mc bo ng cao (HHT)..............................................ccxvi7.9.21. iu khin split range ti bnh n nh nguyn liu..........................................................ccxvi7.9.22. Kh cha x l x ra h thng fuel gas khi thp hp th T-1555 vn hnh khng bnh thng...................................................................................................................................................... ccxvii

7.10. Danh mc theo di kim tra phn xng..................................................................ccxix

8. Normal shutdown........................................................................................................................... ccxxii

8.1. Dng v khi ng li phn xng, cc gi quan trng..........................................ccxxii

8.2. Tm lc cc bc normal shutdown .......................................................................ccxxii

8.2.1. Gii thiu chung.................................................................................................................ccxxii8.2.2. Tm lc cc bc dng thit b phn ng v ti sinh.......................................................ccxxii8.2.3. Tm lc cc bc dng cm thu hi kh v thp tch phn on.....................................ccxxv

8.3. Qui trnh shutdown.....................................................................................................ccxxvi

8.3.1. Gim lng xc tc tn ng trong cc bnh cha xc tc................................................ccxxvi8.3.2. Gim lu lng nguyn liu............................................................................................. ccxxvii8.3.3 Ngng cp du vo Riser..................................................................................................ccxxvii8.3.4 t sch coke............................................................................................................ ......ccxxviii8.3.5 Ngng tun hon xc tc..................................................................................................ccxxviii8.3.6 ng MOV-001 u vo ca thp chng ct chnh...................................................... ccxxviii

8.3.7 Rt xc tc.........................................................................................................................ccxxix8.3.8 Lm ngui phn xng.......................................................................................................ccxxix

8.4 Shutdown tm thi (trong thi gian ngn).................................................................ccxxxiii

8.5 T ng shutdown khn cp (ES).............................................................................ccxxxiii

8.6 Kim tra v bo tr u phun....................................................................................ccxxxiv

8.6.1 Kim tra.......................................................................................................................... .ccxxxiv8.6.2 Bo dng........................................................................................................................ccxxxiv

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8.7 Shutdown khu vc thp phn tch............................................................................ccxxxv

8.7.1 Shutdown thng thng.................................................................................................. ...ccxxxv8.7.2 Gim feed v ngt feed.......................................................................................................ccxxxv8.7.3 ng MOV-001................................................................................................................ccxxxvi8.7.4 ui HC khu thp chng ct............................................................................... ........ccxxxvii

8.8 Shutdown khu vc thu hi kh..................................................................................ccxxxvii

8.8.1 Th tc shutdown khu vc thu hi kh......................................................................... ....ccxxxvii8.8.2 ui HC khu vc thu hi kh.......................................................................................... ccxxxviii

........................................................................................................................................................ ccxxxviii

9. Qui trnh dng khn cp................................................................................................... ........ccxxxix

9.1 Tm tt cc quy trnh dng khn cp........................................................................ccxxxix

9.2 M t chi tit h thng trip khn cp...............................................................................ccxl

9.2.1 H thng dng khn cp....................................................................................................... ccxl9.2.2 Lit k nhng cm iu khin c lp v bo v thit b.......................................................ccxliii

9.3 Dng khn cp phn xng bi ngi vn hnh........................................................ccxlv

9.3.1 Gii thiu..............................................................................................................................ccxlv9.3.2 Mt ngun in cung cp............................................................................................. ........ccxlv9.3.3 Mt ngun kh iu khin.................................................................................................... ccxlvi9.3.4 S c mt h thng air to gi si, air thi v aeration air...............................................ccxlviii9.3.5 Mt hi nc..................................................................................................................... ccxlviii9.3.6 Mt h thng Boiler Feed Water..............................................................................................ccl9.3.7 Mt h thng nc lm mt............................................................................................... ......ccl9.3.8 Mt h thng nc bin lm mt........................................................................................ ....ccli

9.3.9 S c i vi Air Blower.........................................................................................................ccli9.3.10 S c bm nguyn liu ........................................................................................................cclii9.3.11 S c i vi nhng bm khc............................................................................................ccliii9.3.12 Mt h thng fuel gas.............................................................................................. ........... ccliii9.3.13 S c Wet Gas Compressor ................................................................................................ccliv9.3.14 S c ca cc slide valve v plug valve................................................................................cclv9.3.15 Mt iu khin p sut trong thp ti sinh (Slide valve trn ng khi ra xy ra s c)...cclv9.3.16 Mt h thng iu khin......................................................................................................cclvi9.3.17 S c dng du ngc.........................................................................................................cclvi

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1. Cs thit k

1.1 Gii thiu v mc ch ca d nTi liu ny l s tay vn hnh ca phn xng RFCC (phn xng 15) ca d n nhmy lc du Dung Qut thuc Tp on du kh Vit Nam

Cng sut thit k ca phn xng l 69.700 thng ngy (BPSD) ca cn chng ct khquyn t cc loi du th sau:

- Du Bch H

- Hn hp du Bch H v du Dubai

Mc ch chnh ca phn xng craking xc tc tng si du cn (Residue FluidCatalytic Craking) cng ngh R2R l chuyn ha nguyn liu cn thnh cc sn phmphn on nh, c gi tr nh: C3-C4 LPG, xng, nguyn liu Diesel (light cycle oil). Nhcc phn ng ha hc dng hi vi s c mt ca xc tc FCC, cc phn thydrocacbon mch di trong nguyn liu s c b gy thnh cc phn t mch ngn.Xc tc ti sinh nng cung cp nhit cho qu trnh cracking, lm bay hi nguyn liu du c nguyn t ha v to iu kin thun li cho qu trnh cracking nhanh v c tnhchn lc. S ha hi nguyn liu v cc phn ng cracking xy ra trong reactor-risertrong khong 2 giy. Cc sn phm ca phn ng nh kh t, du cn (slurry) v cccng c to thnh trong reactor-riser. Phn ln cc thit b trong phn xng FCCdng cha xc tc, phn tch hi sn phm v tch cc khi xc tc, trong khi chmt phn nh trong h thng c s dng trc tip cho phn ng cracking.

Cng ngh RFCC ca AXENS kt hp 2 tng ti sinh xc tc, h thng phun nhin liung nht, dng iu khin nhit (mixed temperature control), h thng tch cui riser vcc thit b phn phi khng kh, hi nc. Cng ngh thc nghim RFCC ca AXENSc th chuyn ha cn chng ct thnh sn phm vi linh hot cao.

Phn thp chng ct phn tch sn phm hi t thit b phn ng. Cc sn phm gm ducn (clarified oil), LCO v xng nng. ti a sn phm xng, phn xng nng ctrn vi xng nh t phn xng thu hi kh. ti a sn phm Diesel, phn xng nng

s c trn vi LCO.Phn hi v lng nh thp chng ct c x l ti phn xng thu hi kh. Sn phmca phn xng ny gm xng nh, kh t v LPG c x l amine.

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Bng vit tt

ABD A arent BulkDensitAI Attrition Index

API American Petroleum InstituteASTM American Standard forTestin Metalsatm atmos hericCCR Conradson Carbon ResidueCF Coke FactorCRC Carbon on Re enerated Catal stC/O Catal st to Oil ratioE-cat E uilibrium catal stEP End PointFG Fuel GasHC H droCarbonHCO Heav C cle Oil

HDS H dro DeSulfurizationHF H dro en FactorHT H dro en TransferHVGO Heav Vacuum Gas OilIBP Initial Boilin PointLCO Li ht C cle OilLOI Loss On I nitionLPG Li uefied Petroleum GasMAT Micro Activit Testmolwt molecular wei htMON MotorOctane NumberMR Metal ResistanceMTBE Meth l Tertiar But l Ether

PSD Particle Size DistributionRCSV Re enerated Catal st Slide ValveRE Rare EarthREUSY Rare Earth exchan e Ultra Stable zeolite YREY Rare Earth exchan e zeolite YRGT Re eneratorTem eratureRON Research Octane NumberRVP Reid Va orPressureROT RiserOutlet Tem eratureSA Surface AreaSCSV S ent Catal st Slide ValveVAC Vacuum

VGO Vacuum Gas OilTBP True Boilin PointTC Thermal CrackinUCS Unit Cell SizeUSY Ultra Stable zeolite Y

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1.2 Cs thit k

1.2.1 Mc ch v cng sut ca phn xng

Phn xng RFCC c thit k s dng 2 loi cn chng ct kh quyn du Bch H vdu trn Bch H/ Dubai.

Cng sut thit k ca phn xng l 3.256.000 tn /nm phn on cn trn 370oC duBch H, tng ng vi 69.700 thng /ngy vi thi gian lm vic l 8000 gi/nm

Phn xng RFCC cng thit k s dng cn ca phn xng CDU chng ct duchua phi trn t 1.0 triu tn du Dubai v 5,5 triu tn du Bch H. Cng sut khi vnhnh du chua l 3.256.000 tn /nm, tng ng vi 69.700 thng /ngy vi thi gianlm vic l 8000 gi/nm.

Phn xng RFCC cng c thit k x l c cn du Bch H v du trn vi 2phng thc vn hnh nh sau:

- Ti a xng RFCC (max gasoline)

- Ti a LCO (max distillate)

Sn phm c bo m trn c s phn xng vn hnh theo phng thc ti a LCO

Phn xng c thit k x l 100% nguyn liu nng trc tip t phn xngchng ct kh quyn ng thi c kh nng x l 100% nguyn liu ngui t b cha.

Thm vo , phn xng x l kh ca RFCC c th x l cc dng cng ngh:

- Off-gas ca thp stabilizer ca phn xng CDU- Dng LPG t phn xng CDU

Phn xng RFCC cng c th x l dng off-gas t phn xng x l xng (NHT)

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1.2.2 Tnh cht nguyn liu

1.2.2.1 Tnh cht ca cn chng ct kh quyn

Crude (Sour) 100% (Sweet) ASTMBlend Bach Ho Test method

Cut range, TBP C 370+ 370+Vol% on Crude 46.6 47.3

Wt% on Crude 50.0 50.1

API Gravity 26.95 28.9

SG at 15/4C 0.893 0.882

Nitrogen wt ppm 1800 1300

Sulphur wt%) 0.55 0.05 D1266

Conradson Carbon wt%) 2.66 1.57 D189Vanadium wt ppm 10.5 0 D2787

Nickel wt ppm 5 1

Sodium wt ppm 1.6 1.6 D2788

Viscosity @ 50C cSt 43.4 43.4 D445

Viscosity @ 100C cSt 8.8 9

Pour point C 50 52 D97

Asphaltenes wt%) 2.0 1.0 D128

Wax content wt%) N/A 41

Hydrogen wt%) 12.7 12.84 D1018

Neutralization No. mg KOH/gm 0.05 0.05 D3242

Characterization "K" factor 12.58 12.78

ASTM distillation, C(D1160 @ 760 mmHg)

IBP 263 262

10% 379 379

30%) 435 437

50%o 475 480

vol% above @ 550C 32.4 32.5

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1.2.2.2 Tnh cht ca Off-gas t thp stabilizer ca phn xng CDUDng kh ny ly t thp stabilizer ca phn xng CDU v a trc tip vo u ht camy nn kh m ca phn xng x l kh thuc RFCC

Crude (Sour) 100% (Sweet)Blend Bach Ho

Flowrate kg/h 339.0 291.0Composition

N2 mol% -- --

H2S mol% -- --

C1 mol% -- 0.7

C2 mol% 6.3 4.8

C3 mol% 37.0 22.7

iC4 mol% 14.3 16.0

nC4 mol% 40.6 53.5

iC5 mol% 0.4 0.4

nC5 mol% -- --C6+ mol% -- --

H2O mol% 1.4 1.9

Total mol% 100.0 100.0

Molecular weight 50.6 52.6

Lu : cc thng s ca du trn da trn 100% du Dubai

1.2.2.3 Tnh cht dng off-gas t thp stripper ca phn xng NHTH2O kg mol/h 0.13H2S kg mol/h 0.32

NH3 kg mol/h trace

H2 kg mol/h 13.17C1 kg mol/h 1.69

C2 kg mol/h 1.37

C3 kg mol/h 0.83

iC4 kg mol/h 0.06nC4 kg mol/h 0.40

iC5 kg mol/h 0.14

nC5 kg mol/h 0.10C6+ kg mol/h 0.63

Total kg mol/h 18.84

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(kg/h) (243)

1.2.2.4 Tnh cht dng LPG t CDUCrude (Sour) 100% (Sweet)

Blend Bach HoFlowrate kg/h 6206 2071SG at 15C 0.565 0.572

Composition

C2= mol% -- --

C2 mol% 1.2 0.8

C3= mol% -- --

C3 mol% 19.3 10.7

C4= mol% -- --

iC4 mol% 16.5 16.1

nC4 mol% 61.7 71.0iC5+ mol% 1.3 1.4

Total mol% 100.0 100.0

1.2.2.5 Nguyn liu t slopsThp chng ct ca RFCC c th x l cc dng slops

Slops nng: 5.000 thng/ngy

Slops nh: 5.000 thng/ngy

1.2.3 Tnh cht sn phm

1.2.3.1 Tiu chun chng ct

1.2.3.2 Phn xng x l kh

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1.2.3.3 Tnh cht dng kh thi

(sau cm tch tnh in v DeSOx)

Lu cm DeSOx s c lp t sau ny, v trong giai on u x l du Bch Hhm lng Sox trong kh thi nh hn 500mg/m3

1.2.3.4 Tnh cht kh tHm lng H2S: ti a 50ppm trng lng

1.2.3.5 Tnh cht du cn (sau khi tch slurry)Hm lng xc tc: ti a 100ppm khi lng

1.2.3.6 Tnh cht sn phm (d tnh)Case Mixed Bach Ho Mixed Bach Ho

MG MG MD MDLPGSp. Gr15/15 0.565 0.566 0.565 0.565Mercaptans wt ppm 78 7.1 78 7.1COS wt ppm 5.0 5.0 5.0 5.0

Total sulphur wt ppm 3786 332 4260 383Butadiene wt ppm 3012 1647 1358 1063

GASOLINE (C5 - 165C)

Sulphur wt ppm 230 10RON clear 92.0 91.7MON clear 79.5 79.2TVP g/cm 498 531RVP kPa 48 51

Sp. Gr15/15 0.719 0.715

D-86IP 35 34

5 43 4210 47 4630 60 5850 72 7070 91 8990 129 12995 144 143

EP 159 156

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Olefins wt% 43 45

Case Mixed Bach Ho Mixed Bach HoMG MG MD MD

GASOLINE (C5 - 205C)Sulphur wt ppm 340 10

RON clear 92.1 91.8MON clear 79.9 79.6TVP g/cm 337 363RVP kPa 32 34

Sp. Gr15/15 0.736 0.732

D-86IP 39 39

5 50 4910 55 5430 71 7050 90 8770 116 11390 160 15995 176 175

EP 197 197

Olefins wt% 34 35

LIGHT CYCLE OIL (165 - 390C)

Sulphur wt% 0.45 0.04

Cetane number 33.9 38.4Cloud point C -1.8 -0.9Viscosity @ 100C cSt 1.02 1.02Viscosity @ 50C cSt 2.05 2.04Pour point C -17.3 -18.9Flash point C 67 67

Sp. Gr15/15 0.881 0.864

D-86IP 189 189

5 203 20410 212 212

30 239 23950 263 26470 291 29290 333 33495 349 350

EP 373 374

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Case Mixed Bach Ho Mixed Bach HoMG MG MD MD

LIGHT CYCLE OIL (205 - 360C)Sulphur wt% 0.619 0.055Cetane number 24.4 28.1Cloud point C -6.1 -5.3Viscosity @ 100C cSt 0.99 0.97Viscosity @ 50C cSt 1.92 1.88Pour point C -12.8 -14.0Flash point C 76 74

Sp. Gr15/15 0.926 0.911

D-86IP 188 180

5 221 22010 230 23030 245 24550 263 26270 287 28690 323 32295 336 335

EP 353 353SLURRY (390+ C)Sp. Gr15/15 0.994 0.960Sulphur wt% 0.835 0.07Conradson carbon wt% 12.5 9.5Viscosity @ 100C cSt 8.94 6.09Viscosity @ 50C cSt 110 45Pour point C 15-20 15-20

SLURRY (360+ C)

Sp. Gr15/15 1.092 1.043Sulphur wt% 1.03 0.10Conradson carbon wt% 15.7 12.7Viscosity @ 100C cSt 14.5 11.1Viscosity @ 50C cSt 160 140Pour point C 15-20 15-20

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1.2.3.7 LPG composition

BACH HO BLENDMAX MAX

DISTILLATEMAX MAX

DISTILLATE

Component LPG RATE LPG RATE LPG RATE LPG RATE (kg/h)H2S 1 1 1 2H2 0 0 0 0C1 0 0 0 0C2 449 333 444 349ETLN 9 6 9 7C3 6 124 5 179 6 627 5 793PRLN 20 251 14 145 19 625 14 621IC4 14 681 11 273 13 689 10 839NC4 5 801 4 221 7 858 6 560IBTE 6 579 4 679 6 758 5 1701BUTENE 6 317 4 706 5 922 4 653

C2BUTENE 6 482 4 751 5 909 4 592T2BUTENE 9 862 7 245 8 964 6 975BD 106 50 184 6420-50 541 399 540 424TOTAL : 77203 56988 76530 60049

Component LPG (kmol/h) LPG (kmol/h) LPG (kmol/h) LPG (kmol/h)H2S 0.04 0.03 0.04 0.06H2 0.00 0.00 0.00 0.00C1 0.00 0.00 0.00 0.00C2 14.94 11.07 14.77 11.62

ETLN 0.31 0.21 0.32 0.24C3 138.87 117.44 150.28 131.37PRLN 481.23 336.14 466.37 347.44IC4 252.58 193.94 235.51 186.49NC4 99.81 72.63 135.20 112.86IBTE 117.26 83.39 120.45 92.151BUTENE 112.59 83.88 105.54 82.93C2BUTENE 115.53 84.68 105.32 81.84T2BUTENE 175.76 129.12 159.76 124.31BD 1.96 0.93 3.41 1.1820-50 8.07 6.10 8.00 6.47TOTAL : 1518.96 1119.56 1504.96 1178.96

Mercaptan (wt ppm) 7 7 78 78

COS (wt ppm) 5 5 5 5

T (C) 40 40 40 40P (kg/cm2 g) 18 18 18 18Density (P ; T) 530.2 530.1 529.8 529.8

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Density (15C) 563.3 563.0 562.8 562.7

1.2.4 Thng s vn hnh

1.2.4.1 Cm thp phn ng/thp ti sinh

Case MixedMG Bach HoMG MixedMD Bach HoMD

RISER

Outlet temperature CFeed flowrate kg/hFeed temperature CMTC Heavy naphtha kg/hFeed recycle flow kg/hFeed recycle quality HCO back flushkg/h

Total riser recycles kg/h

MTC recycle temperature CHCO back flush temperature CRecycle to feed temperature CRiser steam flow kg/hRiser steam temperature CC/O

Delta coke wt%

520407000

170

76400

0

7605

84005

181

17020350250

6.341.22

518

407000

290

0

0

73797379

170

20350250

5.570.94

511

407000

170

0

117100

HCO

7097

124917

17029020350250 6.430.99

505

407000

290

0

117100

HCO

6875

123975

170 29020350250 5.270.91

DISENGAGER / STRIPPER

Outlet temperature CPressure kg/cmg

Stripping steam flow kg/hStripping steam temperature CEffluent flowrate kg/h

517

1.43

14300

250491907

515

1.43

14300

250425859

508

1.43

14300

250538332

502

1.43

14300

250544699

Case MixedMG

Bach HoMG

MixedMD

Bach HoMD

FIRST REGENERATOR

Dilute temperature CDense temperature CDilute pressure kg/cmgCoke burnt %Flue gas flow kg/h

Air flow kg/hAir blower temperature (*1) CCatalyst dry make-up t/day

678

683

2.28

70282084

261840

210

15.2

646

651

2.28

70194650

181520

232

5.5

641

646

2.28

70231506

215357

223

15.2

631

636

2.28

70178544

166575

238

5.5

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SECOND REGENERATOR

Dilute temperature C

772 734 733 720

Dense temperature C 762 713 712 695

Dilute pressure kg/cmg 1.3 1.3 1.3 1.3Flue gas flow kg/h 138674 94603 114689 86941Air flow kg/h 127775 86942 105427 79856Air blower temperature (*1) C 210 232 223 238

MISCELLANEOUS

Standard conversion wt%V/Ni on EQ-CAT ppmMAT activity wt%Catalyst circulation t/min

79.94

6748/ 3213

68

42.97

80.76 0 /1776

75 37.77

62.60

6748 /3213

55

43.61

61.88

0 / 1776

60

35.72

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1.2.5 Cc iu kin trong ranh gii phn xngKhi phn xng vn hnh theo cng sut thit k, nhit v p sut ca nguyn liu vsn phm nh sau:

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1.2.6 iu kin vn hnh v thit k ca cc dng ph tr

Service Pressure (kg/cm Temperature (C)Normal Max. Min. Design Normal Max. Min. Design

HHP steam 105.5 107.5 103.5 118.2 500 510 490 535

HP steam 42.3 44.3 40.3 48.3 380 400 360 450MP steam 14.1 15.1 13.1 16.8 250 270 230 320LP steam 3.6 4.6 3.6 6.3 160 180 140 230Power station LP 4.1 4.6 3.6 6.3 160 180 148 230Service water 5.0 9.5 1.5 14.2 30 35 15 60

Potable water 2.5 4.0 0.5 5.5 30 35 15 60Demineralized water 5.0 7.5 1.5 11.0 30 35 15 60

HHP BFW 142.0 149.0 138.0 180.0 112 131 105 160HP BFW 60.0 66.0 58.0 72.6 112 131 105 160LP BFW 22.0 24.0 20.0 26.4 112 131 105 160Fresh CW supply 5.2 3.5 5.0 9.2 32 34 25 70Fresh CW return 2.2 2.5 2.1 9.2 47 60 25 70Sea CW supply 3.3 4.0 3.3 7.4 30 30 20 70Sea CW return 1.3 1.4 1.3 7.4 38 40 20 70Refinery fire water 7.0 15.0 3.0 19.3 30 35 15 60Salt fire water 10.0 15.0 6.0 19.3 30 30 20 70HP condensate 7.5 48.3 170 450

MP condensate 7.5 16.8 170 320LP condensate 3.0 6.3 133 230Vacuum condensate(1) 2.5 3.0 2.0 4.7 50 80 50 110Inst. air / Plant air 7.5 8.0 7.0 10.5 35 40 10 65

Refinery nitrogen 7.0 9.0 6.5 11.7 30 40 10 65CCR nitrogen 8.5 9.0 8.5 11.7 30 40 10 65

Fuel gas collection 3.8 4.0 3.5 6.7 46 53 38 75

Fuel gas supply 3.3 3.5 3.0 6.7 40 53 38 75LPG Fuel gas (2) 6.0 34.0 40 140Refinery fuel oil 13 14.0 13.0 20 90 100 50 125

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1.3 Cn bng vt cht

1.3.1 Thp phn ng-thp ti sinh-x l xc tc v x l kh thi

1.3.1.1 Sn lng

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1.3.1.2 Cn bng vt cht chi titINLET, t/h Mixed

MGBach HoMG

MixedMD

Bach Ho MD

CatalystFresh feed

Riser steam

Stripping steam

Recycles

Carr -off from re #2

2578.423407.000

20.350

14.300

81.400

3.050

2266.452407.000

20.350

14.300

5.000

2.812

2616.685407.000

20.350

14.300

122.100

3.250

2143.488407.000

20.350

14.300

122.100

2.706Total 3105.812 2717.047 3184.993 2711.016

INLET, t/h Mixed

MG

Bach Ho

MG

Mixed

MD

Bach Ho MD

Catalyst

Coke

Air

Carry-off from stripper

2578.423

32.854

261.840

2.629

2266.452

22.419

181.520

2.318

2616.685

27.270

215.357

2.699

2143.488

20.605

166.575

2.228

Total 2875.746 2472.709 2862.011 2332.896

OUTLET, t/h MixedMG

Bach HoMG

MixedMD

Bach Ho MD

Catalyst CokeFlue gas Carry-off to lift

2578.42310.759

282.084

4.480

2266.4527.519

194.650

4.087

2616.6859.097

231.506

4.723

2143.4886.932

178.544

3.932

Total 2875.745 2472.708 2862.011 2332.896

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1.4 L thuyt cng ngh

1.4.1 Cc phn ng ha hc v xc tc

1.4.1.1 Gii thiu v mc ch ca mc nyCc phn gii thiu trong mc ny nhm mc ch cung cp y l thuyt c s mtcch n gin nht cho cc mc sau nh: khi ng, vn hnh v dng phn xng...

Mong rng nn tng l thuyt ny s gip ngi vn hnh hiu r hn cc hng dn vnhnh v a ra cc quyt nh sng sut trong cc tnh hung nm trong hng dn.

1.4.1.2 Nhit ng lc hc v ng hcVi bt c phn ng ha hc no, nhit ng lc hc quyt nh kh nng phn ng xyra v s lng sn phm v cc cht khng chuyn ha. Thc ra, mt vi phn ng hon

ton tc l tt c cht phn ng chuyn thnh sn phm. Mt s l phn ng cn bngtrong mt phn cht phn ng c chuyn ha. S lng sn phm v cht phn ngtrong phn ng cn bng ph thuc vo iu kin phn ng v do nhit ng lc hcquyt nh. Cn lu rng nhit ng lc hc khng phi l thi gian phn ng tcn bng hay phn ng hon ton.

ng hc quyt nh tc ca phn ng ha hc (tc l s lng cht tham gia phnng mt i trong mt giy). ng hc (tc phn ng) ph thuc vo iu kin phnng nhng cng c th thay i bng cch s dng xc tc ph hp. Mt phn ng (hay

h phn ng) thng thng c thc y bng mt xc tc ring bit.Ni cch khc, nhit ng lc hc quyt nh thnh phn trng thi cn bng cui cngkhng tnh n thi gian phn ng. ng lc hc d on thnh phn sau khong thigian nht nh. Do cc phn ng xy ra ng thi trong khong thi gian c nh, nglc hc thng c xem xt hn.

Mt cht xc tc thng bao gm cht mang (t oxit, nhm, silicat, magie..) v tch ttrn n cc l kim loi mn.

Kim loi thng m nhn chc nng xc tc. Thng thng cc cht mang cng thamgia nh xc tc ty theo tnh cht ha hc ca n.

Xc tc khng b mt mt nhng c th b mt hot tnh do cc cht bn trong nguynliu hay do nh hng ca sn phm hay phn ng lm ng cc trn xc tc.

Cc mc trong phn ny gm:

- Cc phn ng xy ra trong qu trnh cng nh iu kin vn hnh

- Tnh cht xc tc

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- C ch xc tc

- Tp cht xc tc

- Thng s vn hnh

1.4.1.3 Hot tnh, chn lc v tnh n nh ca xc tcNgoi tnh cht vt l v c hc, xc tc cn c cc tnh cht chnh sau:

- Hot tnh l kh nng lm tng tc phn ng ca xc tc. Hot tnh xc tcc xc nh bng nhit ti xc tc hot ng to ra sn phm t chtlng, cc iu kin vn hnh l khng i.

- chn lc phn nh kh nng la chn cc phn ng mong mun ca xc tcso vi cc phn ng khc

- Tnh n nh th hin s thay i tnh cht ca xc tc trong thi gian lm vic(tc l hot tnh v chn lc) khi iu kin vn hnh v nguyn liu n nh.

Ch yu cc phn ng trng hp hay tch t cc nh hng n tnh n nh caxc tc do lm gim b mt hot ng ca kim loi. Cc tp cht kim loi c mttrong nguyn liu cng lm gim n nh ca xc tc.

1.4.2 Cc loi phn ngCc phn ng xy ra trong cng ngh RFCC gm: cracking nhit v cracking xc tc.

A. Cracking nhit

c trng ca cracking nhit l phn ng b gy mch phn t ca cc hydrocacbon haycc thnh phn khc trong phn on du m

Ch yu l cc phn ng gy mch cacbon-cacbon (-C-C-), cacbon- lu hunh (-C-S-) vng thi tuy t hn l mch cacbon-hydro (-C-H)

Cc phn ng ny l kt qu ca tc ng nhit vi s c mt hay khng c mt xc tc.Tuy nhin do phn ng cracking ny khng hn ch c s b gy phn t nn trongphn on x l c mt c cc phn t mch di hn v ngn hn so vi mch ban u.iu ny c th c gii thch bng c ch phc tp hn xy ra sau cc phn ngcracking s b

n gin ha, mt phn ng craking nhit c th phn bit thnh cracking s b v

phn ng tip dina. Cc phn ng cracking s b

Loi phn ng ny lin quan n nhiu loi phn t khc nhau trong nguyn liu.

Trong cc nhm hydrocacbon chnh: parafin, naphtene, v aromatics cn xem xt cc loiphn ng chuyn ha sau:

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Trong mi trng hp u to thnh sn phm khng no l olefin do khng c hydro.b. Cc phn ng tip din

Lin quan n cc cht trung gian to thnh t phn ng cracking s b. Bao gm

Phn ng cracking th cp paraffins to thnh olefin v paraffin nh phn ng crackings b

Chuyn ha cc olefin hot ha cao

Thnh cc olefin mch ngn hn nh phn ng cracking

Olefin hai olefin mch ngn

V d

Hay thnh diolefin do mt hydro, dehydro l kt qu ca b gy mch cacbon-hydro

Olefin diolefin + hydrogen

V d

Chuyn ha cc olefin thnh prarafin v diolefin hay aromatic, phn ng chuyn hahydro ny ng vai tr quan trng trong phn ng cracking xc tc

Olefin1 + olefin2 parafin + diolefin

Olefins parafin + aromatic

Bt u t cc olefin cho ra sn phm cha nhiu hydro (parafin) hay cha t hdro(diolefin, aromatic)

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Gia cc sn phm trung gian cng c th xy ra cc phn ng tip theo, ch yu l ccphn ng ghp mch ca cc olefin vo aromatic to thnh cc hp cht aromatic nng,y l nguyn nhn to thnh cc sn phm du nng hay cc. Loi phn ng ny cgi l phn ng cng vng Diels Alder (condensation)

B. Cracking xc tcVic s dng xc tc trong cc phn ng cracking hydrocacbon lm thay i r rt ccchuyn ha hc hc, nh hng n c ch phn ng v lm tng tc phn ng mtcch c chn lc

Cracking xc tc khc vi cracking nhit cc im chnh sau:

- Sn lng kh C2 thp, theo l thuyt cc cht xc tc khng cho to thnh ccphn t c t hn 3 nguyn t cacbon

- Tng sn lng xng vi tnh n nh v ch s octan cao hn

- Gim lng cc to thnh vi cng 1 loi nguyn liu x l, cho thy rng sdng xc tc l tt hn

- Cc sn phm vi thnh phn ha hc khc nhau: t olefin, nhiu hydrocacbonmch nhnh, nhiu aromatic..v..v..

T khi c pht minh n nay, xc tc cho qu trnh cracking thay i nhanh chng vngy nay cha ch yu l cc hp cht v nh hnh silicat-nhm v tinh th silicat-nhm,v xc tc mi nht c bit n l zeolite hay ry phn t

Trong qu trnh cracking, hot tnh ca xc tc c quyt nh bi b mt tm axit dng rn trong bt xc tc.

Cc tm axit c x l trong qu trnh sn xut to ra tnh axit thch hp so vi ccaxit lng thng thng nh sulfuric, HCl, nitric axit

Chc nng ca tm axit trong phn ng cracking c gii thch theo hai c ch chnhsau:

- C ch phn ng ring bit vi s tham gia ca cht trung gian l cc cu t ion

- Tc ng chnh trong cc phn ng cho nhn hydro nh cp

Hai c ch phn ng c bit ny gii thch hiu sut ca phn ng cracking xc tc cmiu t di y

Phn ng cracking xc tc c c trng b tnh thu nhit v lm tng s lng phn tv thch hp trong iu kin nhit cao v p sut thp.

a. Phn ng cracking xc tc axit

C ch ca phn ng cracking xc tc axit vi s tham gia ca cc ca cc cu t iontrung gian l tnh cht c trng trong cng ngh cracking

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Cc cu t c to thnh do s hp ph olefin sinh ra trong qu trnh cracking s b trntm axit ca xc tc.

Ngc vi cc phn ng cracking nhit thng khng c tnh chn lc v to thnh ccsn phm nh khng no v sn phm nng hn so vi nguyn liu (c bit to thnh

lng kh ln, xng cha n nh v phn nhiu cc), phn ng cracking xc tc vi cch phc tp hn v c th ci thin sn lng cng nh cht lng ca sn phm theochiu hng mong mun bng cch s dng xc tc. iu gii thch th mnh cacracking xc tc.

Thay i cu trc ca mch hydrocacbon theo chiu hng to thnh cc cu trc mchnhnh. Cu trc mi ny to thnh cc O+ cation n nh hn. iu ny gii thch v saocc cht dng ny c mt nhiu trong sn phm cracking xc tc.

S thay i cu trc din ra mt cch t pht v to thnh cc cacboncation n nh hn, l cc hydrocacbon mch nhnh.

Phn ng cracking th cp to thnh cc olefin mch ngn hn v O + cation mi mchngn v c th phi tri qua qu trnh tng t nh trc. y l qu trnh to thnh ccsn phm nh c trng ca qu trnh cracking. Cc O + cation ngn chn mt cch mnhm vic to thnh cc mch ngn t hn 3 nguyn t cacbon, iu ny gii thch phn ngcracking xc tc thu c t kh C2-.

b. Phn ng chuyn ha hydro

Nh cp trn, phn ng chuyn ha hydro t cc olefin c thc y bi xc tczeolite, cng lc to thnh cc sn phm sau:

- Cc hydrocacbon nhiu hydro, kt qu ca qu trnh chuyn ha hydro l tothnh nhiu parafin

- Cc cu t cha t hydro nh l aromatic

Phn ng di y chng minh phn ng chuyn cc olefin thnh cc hp cht C6

Phn ng bao gm 4 C6 olefin chuyn thnh 3 parafin bng cch nhn hydro v 1aromatic bng cch cho hydro

Loi phn ng ny ng vai tr quan trng trong ton b phn ng cracking bi 2 h qusau:

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- Do phn ng xy ra nhanh nn m bo sn lng xng bng cch ngn chn ccphn ng xy ra ng thi l chuyn ha cc olefin trong xng thnh cc kh nhhn do cracking.

- To thnh sn phm nhiu parafin, c bit trong xng, nh hng n ch s

octan ca sn phm, do cc parafin thu c khng c cu trc mch nhnhTt c nhng gii thch trn cho thy nh hng ca xc tc axit v phn ng chuyn hahydro ng vai tr quan trng v sn lng v cht lng ca sn phm cracking xc tc.

Mt v d khc v phn ng chuyn ha hydro gia naphteno-aromatic (tetraline) v -olefin (isobutene)

Phn ng chuyn ha hydro b chi phi bi:

- Cht lng nguyn liu

- Nhit u ra riser

- T l xc tc trn hydrocacbon

- Oxit t him trn xc tc

- Thnh phn xc tc

Cng nhiu phn ng chuyn ha hydro s:

- Lng cc tng

- Gim LPG- Lng xng tng

- Lng olefin trong sn phm gim

- Xng c ch s octan thp

Nhn qua s cc phn ng cracking song song v tip din ta thy rng tt c cc snphm (kh, xng, LCO v cc) ch l s cp. LCO thng l sn phm ca qu trnhcracking n ca cc phn t mch di trong nguyn liu. Hu ht xng v mt phn khl t cracking s b. Tuy nhin, lng ln cc kh, c bit l C 3 v C4 l kt qu ca

phn ng cracking th cp xng v LCO.Mt phn nh cc to thnh ngay lp tc bi phn ng kh hydro bng nhit t cc phnt mch di nh naphteno-aromatic. Cc hydrocacbon C1 v C2 thng c to ra biphn ng cracking nhit. Cc phn ng trn c th chia thnh 3 loi sau:

1.4.3 Cc phn ng mong munBao gm cc phn ng cracking v ng phn ha

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A. Phn ng cracking

Kh nng phn ng ca cc hydrocacbon

Kh nng phn ng ca cc hydrocacbon c th sp xp theo th t nh sau:

Trong mi trng hp, cracking l kt qu ca qu trnh phn ha cation cacbon (hay ioncarbenium) nm cnh tm axit trn xc tc. Cation cacbon cng d hnh thnh v chimv tr trn b mt xc tc, n cng chu ng phn ha tt. iu ny cng c s s chng minh vic tng kh nng phn ng ca 4 loi phn ng u tin trn:

Kh nng cracking tng theo kch c (hay s lng nguyn t cacbon) v phn nhnhca loi hydrocacbon

Cc hydrocacbon c b gy nh th no?

Mt s quy tc n gin c a ra nh sau

- Cc ankan v anken nng mch thng thng ng phn ha trc khi b b gy.Cc phn t ca sn phm phn ln cha 1 n 2 mch nhnh methyl (hay chaethyl nhng t hn)

- Cracking bng cch phn ha ti v tr ca cc phn t ch yu xy ra vi ccmch trung bnh v thc t v tr ny khng nh hn 3 nguyn t cacbon tnh tcui mch. Cc hydrocacbon C1 v C2 c to thnh bi c ch cracking nhitng th khc vi c ch b gy mch

- Mch alkyl ni vi 1 vng th b ct ti vi tr ni vo vng nu l vng thm vi vi vng naphten th ct ti bt k v tr no t nguyn t cacbon th 3 hocxa hn tnh t u mch

Phn ng ng phn ha

Do c thi gian phn ng ngn trong qu trnh cracking, phn ng ny ch nh hng ncc olefin c nhiu hn 4 hay 5 nguyn t cacbon v cc parafin nng trong nguyn liu.Cc parafin nh c to ra bi cc phn ng cracking s b do khng thi gian ng phn ha. Cc parafin C4 v th tn ti cc t l kh khc bit so vi cc t l

trng thi cn bng nhit ng. Cc olefin C 4 gn hn nhiu nhng khng bao gi tc trng thi cn bng.

1.4.4 Cc phn ng cn c gii hn (nhng khng loi b)A. Phn ng chuyn ho hyr

Phn ng hai phn t ny bao gm qu trnh chuyn mt phn t hyr t mt phn tnaphthen hoc olefin n mt phn t olefin khc bng c ch axt d th. Phn ng ny

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dn n vic hnh thnh cc hyrccbon no, ch yu l parafin, v c cc hp cht thm(n v a vng). Cc hp cht polynaphthenoaromatic v cc hp cht nng to cc(coke precursors) khc l nhng phn t rt d tham gia vo qu trnh chuyn ho hyr.

Phn ng ny ng vai tr rt quan trng i vi cht lng ca xng thu c v qu

trnh to cc. Qu trnh chuyn ho hyr lm gim olefin (olefinicity) ca xng vtng sn lng cc. Phn ng ny cng ng thi lm tng cht lng xng (kh nngxng khng b overcracking) bng vic lm gim hm lng cc phn t d tham giaphn ng.

B. Phn ng trng ngng

Phn ng chnh l qu trnh cng diels-alder. Phn ng ny bao gm qu trnh kt hpmt phn t olefin mch thng hoc mch vng vi mt phn t diolefin mch thnghoc mch vng, dn n vic hnh thnh cc cu trc nhiu vng v khng no. Cc cutrc ny c chuyn ho thnh cc hp cht thm (n hoc a vng) bng qu trnh

chuyn ho hyr, hoc tip tc tham gia phn ng cng vng. Giai on cui cng cacc phn ng cng vng v chuyn ho hyr lin tip l vic hnh thnh cc hp chtthm a vng c kh nng to cc trn xc tc.

1.4.5 Cc phn ng khng mong mun cn c gim thiuA. Phn ng hnh thnh hyr

Phn ng tch hyr t cc phn t mch vng khng no bi cc tp cht kim loi, c thl Ni v V, l yu t c bn dn n vic hnh thnh hyr (Ni v V) v mt phn ccng k (ch yu l Ni). Qu trnh hnh thnh methane hu nh khng b nh hng bi

hm lng kim loi, v th hiu ng ny c theo di thng qua t l H2/methane.B. Hyrccbon C1 v C2

Cc hp cht ny c hnh thnh ch yu do phn ng cracking nhit khng chn la.V th sn lng cc hp cht ny rt nhy cm vi nhit ng phn ng.

1.4.6 Kh nng la chn chuyn ho ca cc h hyrccbon khc nhauHai h hyrccbon chuyn ho mang tnh chn la nhiu nht l alkylmonoaromatic vpolynaphthenes trng ngng (ch yu l cc hp cht hai vng).

Mc chn la to xng ca cc hyrccbon no n gin l: naphthene > isoparafin >parafin mch thng.

Cc hp cht thm a vng, c bit l cc hp cht bn v nm vng, khng chuyn hothnh xng nhng li l nhng hp cht to cc rt tt.

Cc nh ngha v chuyn ho

A. chuyn ho

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chuyn ho c nh ngha bng t l sau:

chuyn ho = lng sn phm chuyn ho*100/lng nguyn liu

Tu thuc vo lng sn phm/lng nguyn liu c biu din bng n v khi lnghoc th tch, chuyn ho tng ng l phn trm khi lng hoc phn trm th tch.

Cc sn phm chuyn ho v khng chuyn ho c quy nh nh sau:Cc sn phm chuyn ho:

Kh kh

C3

C4

Xng nh

Xng nng

Cc

Cc sn phm khng chuyn ho:

LCO

HCO

Slurry

B. chuyn ho dng trong cng nghip ( cn gi l chuyn ho cngnghip)

Trong thc t, vic o lu lng cc sn phm chuyn ho lun gp nhiu kh khn. Lulng cc khng th o trc tip c, v lu lng th tch ca kh kh l hon ton vngha. Ngc li, c th o lu lng ca cc sn phm khng chuyn ho.

Lu lng ca cc sn phm chuyn ho t c bng cch tr lu lng cc sn phmkhng chuyn ho t lu lng nguyn liu.

Lng cc sn phm chuyn ho = lng nguyn liu lng cc sn phm khngchuyn ho.

V vy:

chuyn ho cng nghip = (lng nguyn liu lng sn phm khng chuynho)*100/lng nguyn liu

C. chuyn ho iu chnh

C th hiu rng lng sn phm chuyn ho ph thuc vo im ct gia xng v LCO.im ct ny thng c xc nh bng im si cui ca xng theo tiu chun ASTMti im ct khng i l 2210C (4300F).

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Nu im si u ca nguyn liu nh hn 2210C, lng nguyn liu iu chnh s l:

Lng nguyn liu iu chnh = lng nguyn liu phn on trc 2210C.

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1.4.7 Xc tc

1.4.7.1 Cc c im xc tc

Qu trnh lm vic ca h thng phn ng v ti sinh ph thuc rt cao vo cc tnh chtng hc ca xc tc. Qu trnh lm vic ca h thng tun hon xc tc cng ph thucvo cc tnh cht vt l ca xc tc.

Xc tc FCC (cracking xc tc tng si) l mt axt rn phc tp.

Xc tc FCC hin i gm nhiu thnh phn nh:

Zeolites (Y-type Faujasites, ZSM-5).

Nn hot tnh (silica-aluminas)

Cht ni, kaolin, by kim loi...

Zeolite l nhng hp cht nhm silicat mng tinh th. Tn ti cc quy trnh tng hpzeolite vi cu trc tng t cc hp cht khong bit v c nhng zeolite khng ccht tng ng trong t nhin, nh ZSM-5 s dng trong cc cht ph gia gip tng chs octan. i vi xc tc FCC, zeolite Y-type (Faujasite) c quan tm nhiu nht vi tl silica/nhm vo khong 5.

Khung zeolite c to thnh bi cc nguyn t silicon, nhm v xy, cc nguyn t nyto nn mt cu trc t din vng chc, cc khi t din lin kt vi nhau thnh khi tmmt. Cc nguyn t silicon trong hnh t din SiO 4 c thay th tng phn bng cc

nguyn t nhm v mt s tng ng cc ion natri b in tch. Cc ion natri ny khlinh ng v c th trao i vi NH4+ hoc t him (RE3+). Qu trnh trao i ion ny rtquan trng i vi cc zeolite c s dng lm xc tc cracking nh vic to nn cctm hot tnh cho phn ng cracking.

Cc zeolite trao i vi RE (REY v REUSY) chim u th trong xc tc crackingnh bn v hot tnh cao. Tuy nhin, do t him xc tin cc phn ng chuyn hohyr, olefin v ch s octan gim. Trong sut thp nin 80, hm lng t him cphn gim, v vy cc cng ngh khc c pht trin b li nhng mt mt v bnv hot tnh xc tc.

Kch thc l ca zeolite (0.8 nm) qu nh i vi cc phn t trung bnh ca nguynliu, v vy phn ng tin cracking l cn thit. Nn hot tnh c ng dng to choxc tc mt kch thc l v phn phi hot tnh thch hp, cng nh gip cho ccphn t nguyn liu d dng thm nhp vo cc tm hot tnh cao ca zeolite. Cc nnhot tnh ny cng bo v zeolite t cc cht gy ng c xc tc, nh V v Na. Kch

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thc l v phn phi hot tnh ca xc tc phi thch hp vi cht lng nguyn liuv sn lng sn phm yu cu.

Kaolin c s dng nh mt cht lc v khng trc tip gp phn vo hot tnh xc tc.Cht ni to cho xc tc mt bn t yu cu. Xc tc FCC dng phun kh ngy nay

bao gm cc ht dng cu siu nh c cc tnh cht gi si v chng c mn cao.Kch thc ht trung bnh vo khong 70 micron i vi xc tc sch v hi cao hn ivi xc tc cn bng (E-cat) ph thuc vo hiu qu lm vic ca cc xyclon trong thpphn ng v thp ti sinh.

Kh nng lm vic ca xc tc FCC l kt qu ca nng v hot tnh xc tc ca cccht thnh phn cng nh kh nng cc ht nguyn liu thm nhp vo cc l xc tc.Hot tnh xc tc c quyt nh bi loi zeolite, nng t him, loi nn hot tnh v bn ca cc cu t hot tnh.

Kh nng thm nhp khng ch ph thuc vo nn hot tnh v zeolite m cn ph thucvo cc cu t khng hot tnh trong xc tc.

A. Xc tc sch

Xem chng 4.1, Cc tiu chun k thut ca xc tc

B. Xc tc cn bng

Xc tc cn bng (E-cat) c ly ra t phn xng FCC c th c ti s dng hochu b dng xc tc s dng.

a) Xc tc cn bng c th ti s dng

Xc tc cn bng cht lng tt c th c ti s dng trong phn xng FCC lm xctc khi ng gim mt mt hoc lm xc tc flushing. Ni chung, xc tc ny cc trng bi:

Yu cu xc tc khng hot ho

Tng hm lng kim loi (Ni + V) 3000 v nhiu nht l 5000 ppm.

hot tnh trn 67 wt % MAT.

Kch thc ht trung bnh vo khong 70 micron.

Hm lng ht di 40 micron: trn 10%

Din tch b mt: trn 125 m2/g.

CRC: di 0.1 % khi lng

Hm lng t him: di 1% khi lng.

Gi tr ca xc tc cn bng c ti s dng ph thuc vo nhu cu th trng.

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Trc khi khi ng t nht su thng, kt qu phn tch mu xc tc cn bng FCC cgi n AXENS chp thun trc khi mua.

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b) Hu b xc tc cn bng

Trong trng hp hm lng kim loi (Ni+V) ca xc tc cn bng vt qu 15000 ppm,xc tc cn bng c xem nh xc tc s dng v khng th ti s dng trong phnxng RFCC vn hnh vi hm lng kim loi thp. V vy xc tc cn bng trongtrng hp ny cn c hu b bng con ng m bo an ton mi trng.

c) Ht mn ca xc tc FCC

Cc ht mn ca xc tc FCC thng khng thch hp cho qu trnh ti s dng trongphn xng RFCC v cn c hu b nh xc tc s dng. Tuy nhin, tnh cht cacc ht xc tc mn thch hp lm cht xc tin cho kh nng to tng si i vi ccphn xng gp kh khn trong vic tun hon xc tc.

1.4.7.2 Cch xc tc tnh chn la ca xc tc p ng yu cu cn c mt loi xc tc thch hp cng vicc thng s vn hnh (ch yu l nhit ) quyt nh mc ca cc phn ng khcnhau.

Kh nng lm vic ca xc tc FCC l kt qu ca nng v hot tnh xc tc ca cccht thnh phn cng nh kh nng cc ht nguyn liu thm nhp vo cc l xc tc.Hot tnh xc tc c xc nh bng loi zeolite, nng t him, loi nn hot tnh v bn ca cc cu t hot tnh.

Kh nng thm nhp khng ch ph thuc vo nn hot tnh v zeolite m cn ph thuc

vo cc cu t khng hot tnh trong xc tc.Nn xc tc phi p ng cc tiu chun sau:

Xc tin qu trnh phn tn kim loi bn trong cu trc xc tc cng nh qu trnh

khuch tn cc cht phn ng vo cc tm hot tnh,

C bn c hc cao,

Chu c cc qu trnh x l bng khng kh v hi nc nhit trn 7500C,

Gi c kh nng lm vic tt khi b sc nhit v gp hi nc trong qu trnh ti

sinh.

Xc tc s dng trong cc phn xng cracking phn on cn cn c nung hai lnnhm tng cng bn nhit. phn phi kch c ht phi c kim tra trn xc tcsch. Hm lng ht xc tc t 0 n 20 micron cn thp gim thiu mt mt quacc xyclon. H thng xyclon c thit k gi li xc tc c kch c ht t 0-40micron nhm duy tr cc tnh cht gi si ca xc tc.

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1.4.7.3 Cc tp cht trong xc tcnh ngha

C ba loi tp cht khc nhau cn c xem xt: cht c ch hoc cht trung ho hottnh, cht gy ng c tm thi, cht gy ng c vnh vin.

Nhng ghi ch chung

Danh sch cc tp cht, nh hng ca chng, ngun gc v phng php loi b ctrnh by cc trang sau.

Chng ny a ra mt danh sch cha y v cc tp cht thng gp nht i vimt loi xc tc cho. Cc tp cht khng c lit k y, v lin quan n ccngun nguyn liu khc, c th nh hng xu n kh nng lm vic ca xc tc.

A. Cht c ch hoc cht trung ho hot tnh

Cht c ch l nhng hp cht m cng vi cc cht phn ng trn b mt xc tc lmgim b mt hot tnh ca xc tc. Cc cht ny c hp ph mnh ln kim loi trongxc tc v qu trnh hp ph ny l hon ton khng thun nghch.

Ccbon trn xc tc l mt cht c ch in hnh

theo di hiu qu lm vic ca Thit b ti sinh trong phn xng RFCC cn phi ohm lng ccbon trn xc tc ti sinh. Ccbon trn xc tc t stripper vo l ti sinh(xc tc s dng) cng c th c o nhm cho php phn tch trc tip thng sdelta cc.

Ccbon c chuyn ho thnh ccbon ixit c phn tch bng my d hng ngoi.Ngoi vic o hm lng ccbon trn xc tc ti sinh (CRC), hm lng ccbon c thc d tnh bi ngi vn hnh bng cch so snh mu ca xc tc cn bng vi muca mu tham kho.

Hm lng ccbon cao khng nh hng n hot tnh c o nhng lm mt hottnh hiu qu ca xc tc i vo ng phn ng (thng thng 1-2wt% MAT cho 0.1wt%CRC). Kt qu l chuyn ho v tnh chn la c th thay i. Mt lng khng khv/hoc phn phi xc tc thch hp lm gim hm lng ccbon trn xc tc ti sinh.Hiu qu ca qu trnh loi b ccbon cng bt ngun t vic nng nhit tng c

(dense bed) i vi cc phn xng vn hnh ch chy mt phn.

B. Cht ng c tm thi

Cht ng c tm thi l nhng tp cht c hp ph mnh v tch lu trn b mt hottnh ca xc tc. Vic loi b cc cht ng c v khi phc li hot tnh xc tc c tht c ch vi vic s dng cc quy trnh c trng.

Antimon (Sb)

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Antimon ch c trn xc tc cn bng nu s dng cht th ng ho antimon lmgim hot tnh ca nikel. Khong 30-50% gi tr hm lng nikel lm gim snlng hyr n mc c th chp nhn c.

Cc cht khc

Cc kim loi khc cng c th nh hng n qu trnh lm vic ca xc tc. Chng hnnh, st v ng c th lm tng qu trnh to hyr trong khi canxi v magi c thnh hng n hot tnh v bn xc tc. Thng thng hm lng cc kim loi nykhng ln gy nn nhng nh hng ng ch .

Xc tc cn bng c th cha mt lng nh cc oxt phi kim nh S, P, Cl v cc nguynt nh Li c ngun gc t kaolin hoc cc by kim loi. Lng cn li thng l silica.

C. Cht ng c vnh vin

Cc cht ng c vnh vin khng th loi b c bng cc quy trnh hin hu trong nh

my (thng l qu trnh kh cc bng hi nc v khng kh). Xc tc phi c hub v thay th bng xc tc mi. Nikel, vanai v natri l nhng cht ng c vnh vinin hnh.

Nikel (Ni)

Nikel i vo cng vi nguyn liu v tch t ln xc tc cn bng. Nikel khng bin idi nhng iu kin ti sinh thng thng v c tnh cht nh mt loi xc tc hyrho. Trong phn xng FCC, nikel xc tin cc phn ng cracking khng chn la, cth l nhng phn ng to nhiu hyr v cc.

Vanai (V)

Vanai i vo cng vi nguyn liu v tch t ln xc tc cn bng. Di iu kin tisinh, vanai dch chuyn, c th thm nhp vo xc tc sch v ph hu cu trc cazeolite. Hu qu l hot tnh xc tc v chuyn ho gim. i vi cc xc tc thngthng, mt quy lut chung l hot tnh xc tc gim 2 im cho 1000 ppm vanai iukin vn hnh v lng tiu th xc tc khng i. i vi natri, qu trnh lm gim hottnh ph thuc mnh vo nhit cao nht v p sut hi nc trong l ti sinh.

Bng vic gii hn qu trnh t cc trong tng ti sinh th nht v gi nhit di7000C trong mi trng thiu xy, qu trnh dch chuyn vanai trn xc tc b c ch v

qu trnh ph hu zeolite c gii hn. Dng ph hu ca vanai l dng xy ho honton V2O5 cn nc hnh thnh axt vanait, axt ny ph hu zeolite v lm gim hottnh xc tc. Cc qu trnh xy ho, dch chuyn vanai v qu trnh hnh thnh axt cth c iu khin ngay c trong iu kin c nc/hi nc nu khng c mi trngxy ho.

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Vanai c mt trong nguyn liu v tch t trn xc tc xc tin qu trnh ph hu cutrc zeolite v lm gim din tch b mt hot tnh nhit ti sinh cao.

Natri (Na)

Mt lng nh natri (thng thng 0.1-0.4 wt%) c mt trong xc tc sch. Natri c th

i vo cng vi nguyn liu, c bit l khi x l phn on cn. Trong trng hp hmlng natri trong xc tc cn bng cao, cht lng nguyn liu phi c kim tra. Trongphn ln cc trng hp, qu trnh lm vic khng ng ca cc thit b kh mui hocvic x l cc ngun nguyn liu nhp khu nhim nc bin l nhng nguyn nhnthng gp ca hm lng natri cao.

Natri l cht ng c xc tc lm trung ho cc tm axt v ph hu zeolite. Khi hmlng natri cao, xc tc nhy cm hn vi nhit cao do qu trnh nung nng tng v bmt xc tc b ph hu.

Hm lng natri trong nguyn liu cn c gi mc di 2 ppm khi lng.

1.4.8 Qu trnh ti sinh xc tcXc tc i ra khi stripper thng cha khong 1% khi lng cc vi t l C/H vokhong 1. Mc ch chnh ca qu trnh ti sinh l t cc khi xc tc nhm khi phcli hot tnh xc tc v duy tr cn bng nhit trong phn xng. Lng nhit to ra trongcc phn ng chy c ch ra trong bng di y.

Phn ng Nhit to rakcal/kg ccbon

H2 + O2 --> H2O 28700C + O2 -> CO2 7830

C + O2 --> CO 2200

CO + O2 --> CO2 5630

Tng lng nhit to ra ph thuc ch yu vo hm lng hyr trong cc, mc chyca CO v sn lng cc. Tu thuc vo iu kin lm vic ca stripper v kh nngstripping ca xc tc, hm lng hyr trong cc c th thay i t 6 n 8% khi lng.

Cn ch rng cng vi ccbon v hyr cc cn cha lu hunh v nit. Hai tp chtny c ngun gc t cc hp cht lu hunh v nit trong nguyn liu, cc hp cht nykt hp cng vi cc trong qu trnh cracking. Trong qu trnh chy trong l ti sinh, luhunh v nit to ra cc oxt lu hunh (SO2 v SO3), amnic (NH3) v cc oxt nit(NOx) vi nhng lng thay i tu theo iu kin vn hnh ca l ti sinh. Tt c nhng

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hp cht ny c mt trong khi thi t l ti sinh, l nhng cht gy nhim mi trngv lng thi ra cho php c quy nh bi lut php.

Trong cng ngh R2R, qu trnh ti sinh xc tc c thc hin trong hai l ti sinh clp. Mc ch chnh l:

X l xc tc c hm lng cc cao khng gp phi nhng ro cn v xc tchoc nhng ro cn v luyn kim.

Ti sinh xc tc bng phng php loi cc hon ho (< 0.05 % khi lng)

u tin qu trnh hnh thnh CO so vi CO2 nhm gim thiu nhit t cc. Lng

nhit to ra t qu trnh t CO thnh CO 2 bng khong 2.5 ln lng nhit to rat qu trnh t ccbon thnh CO.

Cho php nhit ti sinh t do dao ng v cn bng vi lng cc tng ngbm trn b mt xc tc s dng.

Gim thiu qu trnh lm gim hot tnh xc tc bi vanai bng vic ngn nga

axt vanait ph hu cu trc zeolite c trong xc tc.

t c xc tc nng trong thi gian tip xc ngn nhm thc y qu trnhtruyn nhit n nguyn liu bng phng php bc x. iu ny c bit c litrong iu kin vn hnh vi chuyn ho cao.

Trong tng ti sinh th nht, qu trnh to CO c u tin nhm gii hn lng nhit tora v loi b nhit t qu trnh vo khi thi.

Vic tng cng qu trnh t CO khng ch to ra nhit nhy cao m cn lm tng lng

khng kh tiu th trn mt tn cc.

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2 M t phn xng

2.1 Cm phn ng ti sinh bo qun xc tc x l khi thiQa trnh R2R l qu trnh cracking xc tc tng si tch hp h thng ti sinh hai tng,h thng bm nguyn liu c bit v h thng tch xc tc c quyn. Qu trnh ckim nghim bng thc t ny loi b hoc lm gim ng k nhng ro cn ca ccphn xng FCC trc y v mang li linh ng ti a chuyn ho cc phn oncn v hn hp ca gasoil v cn chn khng. Phn xng cng ngh bao gm h thngbm nguyn liu, ng phn ng, h thng phn tch ti u ra ca ng phn ng, stripper,l ti sinh tng mt, l ti sinh tng hai, ng rt xc tc, cc ng vn chuyn xc tc vcc h thng iu khin.

Sau y l phn m t ton b cng ngh trong qu trnh R2R.

2.1.1 H phn ng

2.1.1.1 Tng qutHn hp nguyn liu c bm vo y ng phn ng D-1501 v c chia thnh ccdng bng nhau, FIC-003A-F, vo su vi phun nguyn liu I-1501A-F. Nguyn liu gia nhit c nguyn t ho thnh nhng ht nh v trn vi hi nc phn tn ti ccvi phun nguyn liu I-1501A-F v c phun vo ng phn ng D-1501. Cc htnguyn liu tip xc vi xc tc nng ngc chiu v ho hi nhanh chng. Dng nguyn

liu ho hi trn u vi cc ht xc tc v b gy thnh cc sn phm nh v c gi trhn cng vi slurry oil, cc v kh. Dng hi sn phm i ln dc theo ng phn ng vmang theo xc tc. Thi gian lu trong ng phn ng vo khong 2 giy iu kin thitk. H thng bm nguyn liu c thit k mt cch c bit m bo cho cc phn ngxy ra mt cch hiu qu nhm gim thiu vic to thnh cc, kh v slurry oil.

2.1.2.2 Vng bm nguyn liuDng nguyn liu c gia nhit trc khi vo h thng phn ng. Nhit nguyn liucng vi nhit xc tc ti sinh c iu khin to ra mt t l xc tc/du ti u.

Vic bm cht th ng ho kim loi vo nguyn liu trc cc vi phun nguyn liunhm c ch cc nh hng ca nikel ln xc tc. Cng vic ny ch cn thit trongtrng hp x l du hn hp. Cc van shutdown s ct dng nguyn liu n ng phnng v chuyn nguyn liu v bnh cha nguyn liu D-1513 trong cc trng hp khncp. Cc thit b iu khin dng FIC-003A-F iu chnh dng vo su vi phun nguynliu. Nguyn liu phi c phn chia u gia cc vi phun v c theo di bng cc

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thit b hin th dng. p sut PG-003A-F trn mi vi phun c theo di nh l mtvic kim chng dng v biu th trng thi ca cc vi phun.

Tu vo tng trng hp vn hnh, cc dng hi lu khc nhau c s dng cng vinguyn liu.

Trong trng hp x l du hn hp mt MG, dng xng nng hi lu c s dng iu chnh nht ca nguyn liu v xc tin qu trnh nguyn t ho nguyn liu.Mt hiu qu ph l lm gim p sut ring phn ca du nng nhm gip qu trnh hohi c tt hn.

Trong mt vn hnh MD, dng hi lu HCO c s dng nhm lm tng chuyn hophn on nng (HCO v phn on nng hn).

Hi phn tn c cp cho tng vi phun nguyn liu nhm xc tin qu trnh nguyn tho v ho hi nguyn liu. Lu lng hi vo tng vi phun c iu chnh bng ccthit b iu khin dng FIC-005A-F.

Pha di im phun nguyn liu, hi n nh (stabilization steam) c phun vo ngphn ng thng qua bn vi phun I-1503A-D nhm to ra mt dng xc tc ng th tiim phun nguyn liu. Lu lng hi vo mi vi phun c iu chnh bng cc thitb iu khin dng FIC-007A-D.

Cc vi phun MTC (Mix Temperature Control) c t trn vng phun nguyn liu phun dng xng nng ca FCC. MTC ng vai tr rt quan trng trong vic iu khincn bng nhit v ho hi nguyn liu nng. Mc ch chnh l t c nhit caohn ti vng trn nguyn liu.

Ging nh cc vi phun nguyn liu, lu lng MTC v hi phn tn vo cc vi phunc iu chnh bng cc thit b iu dng (FIC-010A-D, FIC-011A-D).

Trong trng hp ngng khn cp, cc van iu khin dng hi vo cc vi phun t ngm ra sch du v xc tc khi ng phn ng.

2.1.1.3 ng phn ng/L phn ngNhit tng nhit nguyn liu (sensible heat), nhit ho hi v nhit phn ng cn thitcho nguyn liu c cung cp bi xc tc ti sinh nng. Nhit u ra ca ng phnng c iu khin bng lng xc tc ti sinh vo ng phn ng qua van trt xc tc

ti sinh. phn Y ti y ca ng phn ng, hi c phun vo thng qua vng hinhm gi cho xc tc trng thi gi si trong sut thi gian lm vic.

Cc phn ng cracking xy ra trong thi gian lu 2 giy trong ng phn ng khi hn hpphn ng i ln dc theo ng phn ng n h thng phn tch u ra ca ng phn ng(ROSS).

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Xc tc nhanh chng c tch ra t hn hp hyrccbon/hi nc ti ROSS nm nh ng phn ng. Qu trnh phn tch ny cn thit nhm ngn chn cc phn ngkhng mong mun to ra kh t xng. H thng ny lm gim ng k thi gian tip xcgia xc tc v hyrccbon sau ng phn ng. Sau khi ra khi ROSS, dng hi i qua

cc xyclon mt tng c hiu sut cao hon thnh qu trnh tch xc tc ra khi hi, vvy gim thiu lng xc tc mt i do cun vo sn phm. Hi sn phm t l phn ngcha mt lng nh cc cht tr, xc tc v hi nc, i vo vng np liu ca thpchng cht chnh T-1501. Mt lng nh xc tc trong hi sn phm i vo dng slurry y thp.

p sut l phn ng dao ng theo p sut thp chng cht chnh v p sut ny khngc iu khin trc tip t cm phn ng. Mt thit b iu p trn bnh hi lu nhthp chng ct chnh D-1514 cho chp t c mt p sut vn hnh n nh trong hphn ng.

ROSS v cc xyclon CY-1501A-F tch hi sn phm khi xc tc s dng v a xctc v tng stripper. Chn cc xycon c trang b bng cc van trickle nhm ngn ngadng kh ngc i vo chn xyclon. ROSS c trang b bng cc chn gn trn bungpre-stripping. Cc chn ny nhng vo trong tng xc tc ca stripper nhm ngn chndng hi ngc.

2.1.1.4 StripperXc tc ra khi ROSS c tin strip bng hi nc t vng hi t ngay u ra cachn xyclon. y l mt c tnh quan trng nhm lm gim sn lng cc. Xc tc tip

tc c strip bng hi nc t vng hi chnh khi xc tc i xung stripper D-1501. Haivng hi ph (vng trn v vng di) cng c trang b cng vi vng hi chnh.Vng trn thc hin giai on hai ca qu trnh tin stripping trc khi xc tc i vostripper. Vng di nm y stripper t c qu trnh gi si n nh ti u voca ng vn chuyn xc tc. Tng lng hi nc c thit k cung cp khong 6 kghi trn mt tn xc tc tun hon. Qu trnh tip xc gia xc tc v hi nc c xctin bng s c mt ca packing tng si cho php xc tc v hi i qua theo dng ngcnhau. Qu trnh tip xc hiu qu cao loi b cc hyrccbon d bay hi c trn v trongcc ht xc tc trc khi xc tc i vo tng ti sinh th nht D-1502. Phn cc cn li

trn xc tc c t trong cc l ti sinh. Xc tc c thi bng khng kh trong ngdn xc tc s dng t c t trng cn thit nhm duy tr p n nh.

2.1.1.5 Qu trnh vn chuyn ca xc tc s dngXc tc s dng sau khi c strip chy xung ng xc tc s dng v i qua vantrt xc tc s dng SV-1502. Qu trnh thi bng kh nhin liu (hoc nit) cthm vo ng dn xc tc nhng im khc nhau nhm duy tr t trng cn thit v cc

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tnh cht gi si ca xc tc s dng. Van trt xc tc s dng SV-1502 iukhin mc trong stripper D-1501 bng vic iu chnh lng xc tc s dng ra khistripper. Xc tc s dng i vo tng ti sinh th nht D-1502 thng qua thit b phnphi nhm m bo cho xc tc b bm cc c phn tn u trn tng ti sinh.

2.1.2 H thng ti sinh

2.1.2.1 Tng qutTng ti sinh th nht D-1502 t 50-80% cc v phn cn li c t trong tng tisinh th hai D-1503. Qu trnh ti sinh hai giai on ny b sung tnh linh ng ng kcho qu trnh nh nhit tim n c loi b trong tng ti sinh th nht dng CO. Khix l cc dng nguyn liu nng, nhu cu loi b nhit cao hn, lng cc c t trongtng ti sinh th nht tng, v th lm gim nhit ca xc tc ti sinh. Khi x l ccdng nguyn liu nh, lng cc c t trong tng ti sinh th nht D-1502 gim, v

th tng nhit xc tc ti sinh. Lng cc c t trong tng ti sinh th nht c ththay i bng vic iu chnh lu lng khng kh t c linh ng trong qutrnh vn hnh phn xng i vi cc dng nguyn liu khc nhau.

Nhit chy to ra t qu trnh t cc c chuyn sang xc tc, nhit ny sau ccung cp cho l phn ng D-1501. Qu trnh cn bng nhit ca phn xng linh nghn nhiu so vi cc h thng ti sinh mt tng do nng lng tim n dng CO t tngti sinh th nht D-1502 c th c iu chnh trong khi qu trnh ti sinh cui cngc thc hin tng ti sinh th hai.

2.1.2.2 Qut gi v l gia nhit khng khKhng kh cn cho qu trnh t cc c cung cp bi qut gi C-1501 dn ng bngtuc bin hi. Lng hi nc c iu chnh tu theo lu lng khng kh hoc tc qut gi.

Khng kh c a vo qut gi C-1501 thng qua b lc v thit b gim thanh F-1501.Khng kh t qut gi c phn b n h thng cung cp kh cho cc vng kh ca tngti sinh th nht, vng kh tng ti sinh th hai, kh nng v vng kh trong ng rt xctc. Van mt chiu nm trn u ra ca qut gi ngn chn dng xc tc ngc trongtrng hp ngng qut gi. Qu trnh surging ca qut gi c ngn chn bng h thng

chng surge c bit.Khng kh n mi tng ti sinh c iu chnh theo lu lng. Lu lng khng khthp mt trong hai tng ti sinh (FXA-170/171) s gy ra tnh trng ngng khn cptrong trng hp s c qut gi. Khng kh vo tng ti sinh th nht D-1502 c phnchia vo hai vng. Vng ngoi v vng trong c thit k tip nhn tng ng 70%v 30% lng khng kh vo tng ti sinh th nht D-1502.

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Cc l gia nhit khng kh (H-1501/H-1502) nm trn ng dn khng kh vo cc vngkhng kh ca tng ti sinh th nht v vng khng kh ca tng ti sinh th hai. Cc lgia nhit khng kh c s dng trong qu trnh khi ng gia nhit thit b bao gmc qu trnh lm kh lp cch nhit. H thng iu khin c lp t phng nga tnh

trng qu nhit ca thit b trong qu trnh vn hnh l gia nhit khng kh v h thngu d la c lp t nhm ngn nga cc iu kin khng an ton trong qu trnh vnhnh u t.

2.1.2.3 Thit b ti sinh th nhtXc tc s dng cha khong 1-1.5% khi lng cc t h thng phn phi xc tc s dng c phn phi u ln tng ti sinh th nht D-1502. Mt phn cc c tchy bng khng kh t cc vng khng kh. L ti sinh ny vn hnh theo ch dngngc (khng kh t di ln v xc tc s dng t trn xung) gip cho xc tc khib qu nhit. iu kin ti sinh c gi mc n ho nhm gii hn qu trnh lm gimhot tnh xc tc v nhit. Tng lng khng kh vo l ti sinh th nht c iu khin gii hn nhit tng ti sinh th nht cao nht l 730oC.

Xc tc ti sinh mt phn i xung thng qua tng ti sinh th nht n im vo ca khnng. Qu trnh thi khng kh ti khu vc ny c thc hin nhm m bo cho dngxc tc trong ng nng c trn tru. Van nt iu chnh lu lng xc tc i vo ngnng v c iu khin bng mc LIC-004 trong tng ti sinh th nht D-1502. Khngkh vo ng nng thng qua trc van nt c iu chnh bng lu lng nng xctc dng long ln tng ti sinh th hai D-1503. Cc im ni dng khng kh khn cp

c lp t lm sch ng nng trong trng hp b tt nghn.Cc xyclon hai tng (CY-1502A-F/CY-1503A-F) tch xc tc khi dng khi thi i rat tng ti sinh th nht D-1502. Ti u ra ca l ti sinh, p sut khi thi c gimxung thng qua van trt hai a SV-1503 iu chnh p sut ca l ti sinh. Qu trnht CO trong khi thi sau c thc hin trong l t CO H-1503. Qu trnh rt xctc lin tc rt cn thit nhm duy tr lng xc tc trong khong vn hnh bnh thng.

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