FCC Unit - A snapshot

Fluid Catalytic Process introduced in 1942, offered an excellent integration

of the cracking reactor and the catalyst regenerator that provides the
highest thermal efficiency. One of the most important processes in the oil
refining industry for converting low value feedstock—primarily vacuum
gasoil coming out of vacuum distillation unit into valuable products
(mostly gasoline and diesel) is fluidized catalytic cracking or FCC.
Enhancing the process or control of fluidized catalytic cracking plants will
yield exciting economic benefits. The behaviour of the fluidized catalytic
cracking process is a major factor in the overall benefits of refinery units.

Fluid Catalytic Cracking Unit (FCCUs) is a secondary

conversion operation within more complex refineries,
and is used to produce propylene, LPG and additional
gasoline, primarily, from the gas oils produced in the
atmospheric and vacuum distillation units.

Fluid catalytic cracking is a chemical process that

utilizes a catalyst and heat to break long-chain
hydrocarbons into smaller-chain hydrocarbons. Typical
products include gasoline, distillate, butane, and
propane fuels. The catalyst is a sand-like solid material
that is fluidized by the hot liquid and vapour fed into the
FCCU. The catalyst flows between the reactor and
regenerator vessels in the FCCU due to this fluidity.

Once the gas oils are cracked by the catalyst and heat,
the resultant effluent stream is sent to a fractionator
that separates the reactor effluent based on boiling
points into several products, including gasoline, light
and heavy gas oils, slurry oil, LPG and butane and
lighter hydrocarbons.

FCC gasoline must be desulfurized and reformed before

it can be sent to blending for the finished gasoline
product. Light cycle oil is also desulfurized before it is
blended into finished diesel or heating oil. Slurry oil can
be sent to a Coker for further processing or blending
into residual fuel oil. Fractionator overhead gases are
separated into fuel gas and LPG (for further processing).

Carbon, referred to as catalyst coke, is deposited on the

catalyst during the cracking process, and reduces the
catalyst’s capacity to crack the gas oils. The coke is
burned off the spent catalyst in the Regenerator, which
also reheats the catalyst to the temperatures required
for the reactor. Flue gas produced in the Regenerator
exits the vessel overhead and is routed to heat recovery
equipment and then to environmental control
equipment and then discharged to the atmosphere.
Feed

1. Hydrotreated Hot VGO (Vacuum Gas Oil)

2. Hydrotreated cold VGO from the FCC feed storage
tanks
3. Low Sulphur Waxy Residue
4. Crude from Various Country

Product
1. Fuel gas (Can be utilized as fuel in the refinery fired heaters
or for value creation can also be used as a feed to Off Gas
Cracker unit for recovery of ethylene and propylene which
in turn can be used as building blocks for petrochemicals
like Polyethylene and Polypropylene)
2. LPG (Butane, Propane, Propylene)
3. C5 product used for blending in gasoline or can be used as
feedstock for Selective Hydrogenation Process and Tertiary
Amyl Mether Unit which produces high octane blending
component.
 4. Light Naphtha (C6-115 °C), routed to Light Naphtha
Hydrotreater or used as gasoline blending component.
5. Heart cut naphtha (115-165 °C), routed to Heavy Naphtha
Hydrotreater Unit from where hydrotreated product can be
processed further in reformer unit for production of
aromatics. It can also be used as gasoline blending
component.
6. Heavy Cracked Naphtha (180-215 °C), is used as Gasoline
blending component.
7. LCO can be used as a Diesel blending component. It can
also be fed to LCO Hydrocracker unit for production of low
sulphur diesel and gasoline.
8. Main Column bottom Clarified Slurry Oil is used as Fuel Oil
for firing in heaters or it can also be sold in market as
Carbon Black feed stock.

Importance of FCC:
There are three important processes for converting vacuum gas oil to
lighter, more valuable products within a refinery, namely.

1. Thermal Cracking
2. Fluidized Catalytic Cracking
3. Hydro cracking

When the aim is to maximize the lighter components (LPG, olefins,

and petrochemicals feed stocks) FCC is the ideal choice. Also, FCC
based complex is 15-20% cheaper than a comparable Hydro
cracking Unit for VGO conversion.

Depending on the needs of the operation, the FCC unit can function in a
variety of modes. The utilization of an intermediate cracking temperature
(510 to 540°C), high catalyst activity, and a high catalyst/oil ratio define
the Maximum Gasoline mode.
The Maximum Middle Distillate mode of operation is a low-cracking-
severity operation where light cycle oil generated during initial cracking is
prevented from re-cracking by keeping the first pass conversion low.
Reducing the catalyst/oil ratio and the riser exit temperature (below
510°C) both lessen the severity.

Maximum Light Olefin Yield: By raising the riser temperature over 540°C
and using catalyst additions including ZSM-5, it is possible to boost the
yields of propylene and butylenes above the maximum gasoline operation
mode.

Mode of operation of FCC is decided based on the market pricing of

products and business scenario. FCC is considered as one of the main
profit centre of refinery.

Reactions

1 Cracking

It is the main reaction occurring in the unit. It is an endothermic

reaction in which larger paraffinic molecule breaks down into
smaller olefins and paraffin molecule and larger olefin further
breaks down into smaller olefin thus producing high value lighter
products from heavier vacuum gas oil.

Paraffins -> olefins + smaller paraffins

Olefins -> smaller olefins

Aromatic side chain scission

Naphthenes -> olefins + smaller ring compounds

R-C+H –CH2-CH2-CH2-CH3 ------> CH3-CH=CH2 + C+H2-CH2-CH2R

2 Isomerization:

Olefins -> Iso-olefin

Paraffins -> Iso-paraffin

CH3-CH2-C+H-CH2-CH2R -----> CH3- C+ - CH – CH2R

| |
H CH 3

Isomerization reaction helps in improving the octane of gasoline

and lowering the cloud point of diesel.

3 Hydrogen Transfer:

Hydrogen transfer or hydride transfer is a bimolecular reaction in

which one reactant is an olefin ex. reaction of two olefins. One of
these olefins becomes paraffin and the other becomes cyclo-
olefins.

Hydrogen transfer reactions increase FCC Gasoline yield and its

stability. Some of the drawbacks are:

• Lower gasoline octane

• Lower light olefins in the LPG

• Higher aromatics in the gasoline and LCO.

Naphthene + olefins -> Aromatics + Paraffin

Olefins -> Paraffins + Aromatics

4 Dehydrogenation
5 Dealkylation

6 Condensation

Process flow Description.

Feed Preheating Section:

The combined stream of hot VGO from VGO hydrotreating units,

LSWR from RTF, and cold VGO from FCC feed tanks enters the
raw oil feed surge drum. Raw oil is pre-heated in this section.

Reactor – Regenerator Section

• Raw oil is atomized by the optimix nozzles and enters the

reactor via riser.
• Riser is the heart of the reactor where all the reactions take
place.
• Hot regenerated catalyst enters the riser via catalyst slide
valve.
• Catalyst is fluidized in the riser where catalyst particles and
oil get contacted and cracking and other reaction occurs.
• During the reaction, coke gets deposited on the catalyst
surface.
• Catalyst and product vapour reach to the reactor top in 2 to
3 seconds.
• Catalyst and product vapour get separated by the cyclone
separators.
• Catalyst flow down to the reactor stripper where the
product vapour is stripped off from the catalyst with steam.
• From there, catalyst enters the regenerator for
regeneration by coke burning.
• Product vapour at around 530 to 550 °C enters the Main
Column.
 • Regenerator consists of 2 sections combustor and
regenerator.
• In the regenerator, catalyst is regenerated by burning off
the coke at around 700 to 750 °C. Air required for
combustion is provided by Main air blower.
• Flue gases are passed through two stages of cyclones to
separate the catalyst particles from flue gas. Regenerated
catalyst is sent to reactor through slide valves.

Power Recovery Trains

• The power recovery train comprises mainly of five sections

called Expander, Main air blower, Steam Turbine, Gear Box,
Motor/Generator.
• Expander, MAB, and Steam turbine are mounted on a single
shaft and are connected to the motor/generator via
gearbox.
• Flue gas coming from the regenerator enters the third
stage separator. The catalyst particles are separated from
the flue gases.
• Form the TSS, one stream is sent to the FGC via orifice and
other stream is sent to the expander. Flue gases passed
through the expander and the dynamic energy of flue gas is
converted into mechanical energy which is used to drive
the MAB.
• Flue gas from the expander and from the orifice enters in
the Flue Gas Cooler (FGC) where heat of the flue gas is
utilized to produce High Pressure steam.
• From the FGC, cooled gas is released to the atmosphere via
stack.
• From the TSS, one stream is sent to the Fourth Stage
Separator for further separation. The entrained catalyst is
disposed, and the flue gas form the FSS goes to stack.
Main Column Section:

The cracked oil vapours from the reactors at 550 degrees Celsius
are fractionated in the main column sections. Product vapours
from the reactor enter main column, and it has trays at the
bottom section.

• From the main column, we take out HCN cut at 171 °C. This
HCN stream is sent to the HCN stripper where with the help
of steam, we strip out lighter end in HCN and thereby we
maintain flash point of HCN product. After that this product
HCN is cooled and is used for gasoline blending, gas turbine
fuel or for blending in fuel oil.

• We draw LCO cut at 236 °C from main column. This LCO

stream is sent to the LCO stripper where with the help of
steam lighter ends are stripped out and the product LCO is
sent to LCO Hydrocracker as feed where it is used for the
production of diesel and gasoline. LCO can also be used for
blending directly into diesel up to the limit so that the
diesel specifications are maintained. It can also be used as
GT fuel.

• We have HCO cut at 325 °C from the main column. We

don’t use this stream as product stream but for condensing
the product vapour, we draw off this stream and after
cooling it in various heat exchangers we feed it back into
the column at 208 °C.

• The bottom product is CSO. Main Column Bottom slurry is

passed through various steam generator for heat recovery.
High Pressure steam is produced in the steam generators. It
 can also be passed through various heat exchangers for
heat recovery and unit heat integration and there by
cooling the slurry. Some portion is drawn off as Clarified
Slurry Oil product which is used as fuel oil in heaters and
boilers. Remaining portion is fed back to the column. CSO
product can also be sold in the market as fuel oil or as a
carbon black feed stock.

Unsaturated Gas Concentration Sections

• Unsaturated product vapour from the main column

overhead is sent to the reflux drum via fin fan cooler. Some
portion of the reflux drum is sent to the main column as
reflux while other portion is sent to the main column
receiver.
• Vapor stream from the Main column receiver is sent to the
WGC where all the gases are compressed and heavier are
liquified and thereby, we can separate the compounds.
Wet gas compressor is a steam driven machine.

Primary Absorber:

• From HP receiver, liquid stream is fed to primary absorber

where it is stripped out of heavier compounds from gas
stream and there by recover C3 and C4 compounds from
gas stream.
• Overhead stream of Primary absorber is still containing C1,
C2 and C5+ component which is sent to Sponge absorber
where C5+ components are recovered by the circulating
LCO stream. This LCO stream is sent back to the main
column.
 • C1 and C2 gas stream is sent to the amine absorber via
lean gas KOD. In amine absorber H2S is removed by
absorbing in lean amine solution. MDEA is used as the
amine for absorption of H2S. Lean amine absorbs H2S and
becomes rich amine.
• After absorbing the H2S, rich amine solution is then sent to
the sulphur unit for sulphur recovery and production of
Sulphur. Overhead product vapour (C1 and C2) is sent to
fuel gas header. It can be used as fuel in refinery fired
heaters, gas turbines and boilers. It can also be utilized as a
feed to off gas cracker.
• The bottom product of the primary absorber containing C5
is sent to the HP receiver. The liquid stream from the HP
Receiver is directed to a stripper column where lighter
gases, specifically C1 and C2 are removed from the liquid.
The stripped gases are then reintroduced into the gas
concentration section for further processing.

Fractionation Section

Debutanizer:

The bottom product of the HP receiver is sent to stripper. Here

the lighters are stripped off with the help of steam. Stripper
bottoms is sent to the Debutanizer column. In this column mainly
C3 and C4 is separated from the other components and removed
from the top of the debutanizer. It is sent to the LPG Merox unit
and form the bottom product of Debutanizer one part is sent to
the primary absorber and other part is sent to the de-pentanizer.

De-pentanizer:
From the top section of the de-pentanizer, we recover C5
component and sent it to the SHPTAME (Tertiary Amyl Methyl
Ether) unit. Some portion of the same can be used as a feed to
light naphtha hydrotreater unit also. Side cut from the de-
pentanizer column can also be used as feed to selective
hydrogenation unit. Bottom product from the de-pentanizer
column is sent to the Naphtha Splitter Column.

Naphtha Splitter Column:

From the NS-divided column, three streams are collected as a

product. NS-top product which is light naphtha is sent to the
gasoline blending. It can also be sent to light naphtha
hydrotreater as a feed. It can also be used as a feed to FCC
reactor riser for cracking and generation of lighter olefinic and
other lighter products. Part of the overhead product is sent to the
De-isohexanizer. Side cut, Heart cut naphtha is sent to the
gasoline blending and HNUU as a feed. After hydrotreating, heavy
naphtha product is fed to reformer unit for conversion to
aromatics. Reformer product can also be used for blending in
gasoline. Bottom product of the NS column Heavy Naphtha is
sent to the Scanfining unit. Here sulphur content is reduced and
the low sulphur product can be used for gasoline blending. It can
also be used directly for gasoline blending.

De-Isohexanizer:

In De-isohexanizer, top product is C6 which is benzene is sent to

aromatics unit and bottom product, heavy naphtha is sent to
reactor riser, Scanfining unit and to LMOG unit.

Major Equipment Description:

Reactor:
 • The reactor facilitates an endothermic cracking reaction,
where raw oil is subjected to high temperatures.

The ‘reactor’ consists of three parts namely, the reactor, the

stripper, and the riser.

Riser:

• The recycle slurry oil from the bottom of the distillation

column is mixed with the preheated high-boiling petroleum
feedstock (at about 315 to 430 °C) and injected into the
catalyst riser, where it is vaporised and cracked into
smaller molecules of vapour by contact and mixing with the
extremely hot powdered catalyst from the regenerator.

• All the cracking reactions occur in the catalyst riser within

2-4 seconds. The hydrocarbon vapours 'fluidize' the
powdered catalyst at a temperature of about 530 °C and a
pressure of about 1.70 bar, and the resulting mixture flows
upward into the reactor.

• Riser is 51.1m long and extends well into the stripper. The
riser termination is a UOP patented vortex Separator
system having three disengaging arms. Riser has the UOP
patented Optimix nozzles for feed injection.

Reactor:

• The reactor is a disengaging vessel for the catalyst and

hydrocarbon mixture exiting the reactor riser.
• The top of the vessel, the lower section above the stripper
and the reactor riser above the stripper are lined with abrasion
resistant lining for erosion protection. The vessel operates at 546
°C.
Stripper:

• Spent catalyst from the riser contains some entrained

hydrocarbon vapours. Steam is used to strip these
hydrocarbons from the catalyst in the reactor stripper.

• The spent catalyst flow downwards through a steam

stripping section to remove any hydrocarbon vapours
before returning to the catalyst regenerator.

Cyclones:

• The spent catalyst is separated from the cracked product

vapours by passing through a set of two-stage cyclones
inside the reactor.
• The catalyst bearing gas enters a cylinder through a
tangential opening. The catalyst is 500-1000 times as
heavy as the gas and is subjected to forces several hundred
times that of gravity as the gas swirls around the cylinder.
The larger particles are removed through inertial forces,
which tend to keep the particle moving in a straight line to
collide with the wall, and centrifugal forces, which tend to
throw the particle outward to collide with the wall. The
collisions slow down the particle and it tends to fall. Two
important factors in cyclone efficiency are the velocity of
the gas and the size distribution of the particles. Flapper
valves with counterweights are used at dip leg ends. The
flow of spent catalyst to the regenerator is controlled by a
sliding valve in the waste catalyst line.

Regenerator:
 • Regenerator is a two-part cylindrical vase supported by a
skirt. The disengaging space for the catalyst and flue gases
departing the combustor is at the top, while the combustor
itself is at the bottom. Within the regenerator are stages of
cyclones. The regenerator's top supports these cyclones.

• The spent catalyst from the reactor mixes with the blower
air at the bottom of the combustor

• The coke is burnt off the catalyst as it travels up the

combustor riser. Regenerator cyclones are used to remove
the catalyst from the flue gas produced when the FCC
catalyst burns coke or ore with air. The catalyst settles to
the dense phase. From here part of the catalyst goes to the
base of the reactor riser, and the rest back to the
combustor They are made to endure extremely abrasive
service at 760 degrees Celsius.

• The plenum chamber is where the exit flue gases from the
second stage cyclones are gathered. The regenerator is
positioned above the combustor. To distribute air, an air
grid is placed at the bottom of the combustor.

Power Recovery Trains:

• FCCU has two power recovery trains which uses flue gas to
produce power which is used to drive main air blower. Main
air blower is used to supply air to regenerator.
• The power recovery train comprises mainly of five sections
called Expander, Main air blower, Steam Turbine, Gear Box,
Motor/Generator. Expander, MAB and Steam turbine are
 mounted on a single shaft and are connected to the
motor/generator via gearbox.

Flue Gas Cooler:

• FGC is used to cool the flue gas coming from the

regenerator. It consists of Economiser, Evaporator and
Super-heater. The heat of flue gas is utilized to produce HP
steam and the cooled flue gas is released in air via stack.

FCC Catalyst:

• The FCC catalysts in use today, referred to as zeolites.

• These have become the industry standard FCC catalysts
due to their high activity, stability, and superior catalytic
properties.
• They are very resistant to breakage and thermal
deactivation. They yield a product distribution containing
more gasoline, less dry gas, and produce less coke. The
catalytic activity occurs at what are termed acid sites
where the catalyst cracks gas oil molecules selectively to
gasoline and lighter materials without significant coke
formation.
• Total surface area, mean surface area, zeolite surface area,
attrition index, particle size diagram are few of the
important properties of FCC catalyst. For FCC unit, cost of
the catalyst is one of the major operating cost item.
Reduction of catalyst cost can further increase the
profitability of unit. In addition to FCC catalyst, certain
additives like ZSM-5 are also added. Addition of this is done
to increase the lighter yields especially ethylene and
propylene.
Role of Distillation in FCC Unit:

• Distillation is a separation process based on

differences in boiling temperatures or relative volatility of
liquid-liquid solutions. Mixed feed streams are divided into
their own unique products using distillation columns.
• Crude Oil Distillation Process
Different components of crude oil have distinct sizes,
weights, and boiling temperatures; they can be readily
separated by a procedure known as fractional distillation.
The procedure for fractional distillation is as follows:

Differently boiled liquids are cooked to a high temperature

in one or more cases. Generally, feed to the unit is heated
with the help of fired heater. High pressure steam is used to
accomplish this, raising the temperature to roughly 1112
degrees Fahrenheit or 600 degrees Celsius.

The mixture turns into vapor as it boils (gases).

The vapor travels through the trays or plates of the

distillation column as it enters. The perforations or bubbles
in the trays allow the vapor to travel through with ease.
They aid by lengthening the vapor's duration of contact
with the liquids in the column.

1. Feed Introduction
 Cracked Product Inlet: The feed to the distillation column
consists of the vaporized and liquid products from the FCC
reactor. This mixture includes a range of hydrocarbons,
from light gases to heavier oils.
2. Column Design and Structure
 Trays or Packing: The fractionator is equipped with trays
and structured packing that facilitate vapour-liquid contact.
Each tray or packing section allows for mass and heat
transfer, promoting equilibrium between rising vapours and
descending liquids. Contact between the liquid and vapor
happens either on the surface of trays or the packings.
Trays can be of different types sieve trays, valve trays
(fixed valve trays or moving valve trays), bubble cap trays.
In modern world there are special trays also like multi
downcomer trays, enhanced capacity multi downcomer
trays, super frac trays etc. Trays can be 2 pass, 4 pass etc.
Each tray has several tray panels which are bolted
together, each tray has weir which maintains the liquid
level on the tray for the vapor and liquid to contact each
other and for the mass transfer to happen. Liquid from the
upper tray flows down to lower tray through down comer.
Downcomer clearance which is the gap between
downcomer and the bottom tray is very important along
with the weir height for tray efficiency and performance of
distillation column.
Packings can be either random packing or structured
packing.
 Heat Source: The column is typically heated at the bottom
using reboilers, which provides the necessary energy to
vaporize heavier components.

3. Separation Mechanism
 Rising Vapours: As the feed enters the bottom of the
column, heat causes lighter hydrocarbons to vaporize.
These vapours rise through the column.
 Descending Liquid: Heavier fractions, which condense on
the trays, flow downwards, providing the opportunity for
mass transfer between the vapor and liquid phases.
 4. Vapour-Liquid Equilibrium
 Boiling Point Differences: The separation is based on the
principle of boiling point differences. Lighter fractions, such
as gases and naphtha, have lower boiling points and will
tend to rise, while heavier fractions condense and fall.
 Equilibrium Stages: Each tray or packing section acts as
an equilibrium stage, allowing for the continuous exchange
of mass and energy. As the vapor rises, it becomes
enriched in lighter components, while the liquid descending
becomes enriched in heavier components.

Products of FCC are Fuel gas, LPG, C5 as SHP feed, Heart cut
naphtha, Heavy cracked Naphtha, LCO and CSO.

Important quality parameters for various products are as

follows:

Fuel gas:H2, H2S, Methane, Ethane, Ethylene, Propylene

LPG: Propylene, H2S, C5’s, C2’s

C5 feed: Isopentane, N-pentane, pentenes

Gasoline: Distillation, Density/RON/MON/Sulphur content

LCO: Distillation, Density, Flash Point, Sulphur

CSO: Distillation, Density, Viscosity, Bottom sediments,

water content, sulphur content

For achieving the desired properties of the products, Efficient

performance of the distillation columns is of utmost importance.
Properties of all the products is achieved by proper operation of
the distillation column. Sharp separation of the cuts is very
important to achieve all these properties of products.

All the product properties are controlled by controlling the draw

off temperature, draw off flow rates, column pressures, column
temperatures, heat removal, reflux rate, reflux ratios, re-boiling
duties etc.

It can be seen that if the distillation column performance is not

upto the mark, it can lead to loss of valuable components and
streams into less valuable products. For example if naphtha is
formed but due to improper separation if it drops into LCO then
valuable lighter stream ends up into heavier stream which can
impact the overall economics.

Improper separation in distillation column can also lead to off

spec product as the final product quality is achieved through
distillation only.

Thus it can be seen that only formation of the product through

reaction in the reactor is not important. It is because the products
formed in reactor are required to be distilled within the
specifications so that the high value products along with its
properties are separated and produced. Yield of gasoline and LCO
which is a diesel component can be higher from the reactor but if
the separation is not proper and if it drops down into CSO, it is a
loss. If H2S and lighters are not removed properly from HCN and
LCO in stripper, its flash point will reduce and will not be able to
sale the product. It will fail in flash point. Thus removal of lighter
and other components as per the specifications of distillation
column is very important.

Following section describes the importance and function of major

distillation column along with the key handles to control the
quality parameters of the various FCC products.

Main Column:

Main column is divided into 2 parts. Top is the regular

fractionator and lower section generally has disc and
doughnut trays.
Operation of the main column is very important from the unit
and refinery profitability perspective as the separation and
recovery of the high value product is of utmost importance
which is achieved by proper distillation.

Side cut streams must be stripped to remove the absorbed

light material.

Heavy cut naphtha and LCO stripper adjust the flash point of
HCN and LCO. Final boiling point and density are the main
parameters for this product. It is controlled by adjusting the
draw off flow, reflux, pressure and temperature.

LCO FBP can be controlled in distillation column by adjusting

the draw off flow of LCO, pressure, reflux and temperature.
Flash point is adjusted in column by controlling the steam flow.

Primary Absorber:

Primary absorber is a trayed column. Its main function is

recovery of propylene, propane, butane, butylene from the HP
receiver gases.

Sponge Absorber:

Function of this column is absorbing propylene, propane,

butane, butylene, C5 in the gas stream from primary absorber.
It’s a packed column.

Stripper:

It is used to strip off the light ends C3 content and H2S from
the HP receiver. Stripper bottoms is free from H2S and is sent
to debutanizer.

Debutanizer:

It helps in recovery of C3 and C4 in the top of the column.

Parameters to be controlled in LPG are H2S, C2s and C5
content. Presence of C2 can be due to poor separation. C5
content in LPG which indicates weathering can be controlled in
DB column by controlling DB temperature, pressure and reflux
flow.

Depentanizer:

It helps in separation of C5’s from C6+ Naphtha. C4’s, C6’s

and total sulphur are few of the important parameters to be
monitored for C5’s feed going to downstream unit. This is
controlled by adjusting bottom temperature, reflux, pressure
and reboiling in DB and DP columns.

Naphtha Splitter:

The function of this column is to separate full range naphtha

into Light Naphtha, Heart cut naphtha and heavy Naphtha.

Heart cut Naphtha is fed to Heavy naphtha hydrotreater and

subsequently to reformer and aromatics complex for aromatic
production. It’s FBP is of utmost importance. It’s FBP and IBP is
controlled by adjusting the column temperature profile.

De-isohexanizer:

Function of this column is to separate depentanizer bottoms

into Isohexane, Benzene and light naphtha.

5. Product Withdrawal
 Overhead Products: The lighter fractions exit the top of
the column, typically including gases (e.g., propane,
butane) and light naphtha. These can be further processed
for recovery of propane, butane, propylene or sent to
storage. Propylene can be further used to produce
polypropylene.
 Side Draws: Some distillation columns may have side
draws that allow for the extraction of intermediate
products, such as kerosene or other light distillates.
 Bottoms Products: The heavier fractions that do not
vaporize are collected at the bottom of the column, which
may include heavy cycle oil. This material can be sent back
to the FCC unit for further cracking or processed in other
refining units.
6. Heat Recovery and Energy Efficiency
 Reboiler: The reboiler at the base of the column provides
heat, promoting vaporization. It recycles some of the
energy, enhancing efficiency. Re-boiling duty is provided
first by heat integration of high temperature product and
after utilizing the heat from hot products, further heat input
is provided by steam.
 Condenser: At the top of the column, a condenser cools
the overhead vapours, causing them to condense into
liquids that can be collected and separated. Combination of
water coolers and air coolers is used to condense the
overhead product.

7. Control Systems

Effective controlling of the distillation column

parameter is very important which in turn is
dependent on robust functioning of the control
system.
 Temperature and Pressure Monitoring: The column is
monitored closely to maintain optimal temperature and
pressure conditions, which are crucial for efficient
separation.
 Reflux monitoring: Reflux rate and ratios is very
important for achieving product quality.
 Automation: Modern FCC units often use automated
control systems to optimize distillation operations, ensuring
product quality and maximizing yields. Automation is done
in FCC and other refinery unit in the form of Advance
process control and real time optimizers. This not only
reduces the manual dependency for the plant operation but
also helps in continuous optimized operation of distillation
section thus helping to achieve the objective function of
reducing operating costs and maximizing profits out of the
unit.