Abstract
Fluidized catalytic cracking (FCC) unit has vital role in the process of modern refineries because this unit is used for production of valuable refinery products. The aim of this research is to study different capacities of the feedstock in FCC unit and to find the maximum available capacity with consideration of technical and economic criteria. In this regard, process simulation of this unit is performed in the Aspen HYSYS software. Next, this process simulation is imported to Aspen Capital Cost Estimator (or ICARUS) for operating cost (OPEX) and capital cost (CAPEX) evaluations. Finally, it is tried to optimize the capacity of fluidized bed catalytic cracking process. By investigating the results, it was revealed that the breakeven point (BEP) in this unit is in the capacity of 30 000 barrels per day. It means that total cost (operating and capital costs) and net profit (revenue of products) are equal and at the higher capacities than this BEP, FCC unit has profitability. Based on the economic analysis, it could be found that CAPEX and OPEX in the BEP capacity will be more than 156 618 948 $ and 37 432 199 $/yr, respectively.
Similar content being viewed by others
REFERENCES
Daminev, R.R., Chanyshev, R.R., Latypova, F.N., Vil’danov, F.Sh., and Karimof, O.Kh., Petrol. Chem., 2015, vol. 55, pp. 683–685. https://doi.org/10.1134/S0965544115080034
Chernysheva, E.A., Piskunov, I.V., and Kapustin, V.M., Petrol. Chem., 2020, vol. 60, pp. 1–15. https://doi.org/10.1134/S0965544120010053
Gorbunov, D.N., Nenasheva, M.V., Matsukevich, R.P., Terenina, M.V., Putilin, F.N., Kardasheva, Yu.S., Maksimov, A.L., and Karakhanov, E.A., Petrol. Chem., 2019, vol. 59, pp. 1009–1016. https://doi.org/10.1134/S0965544119090056
Khadzhiev, S.N., Gerzeliev, I.M., Kapustin, V.M., Kadiev, Kh.M., Dement’ev, K.I., and Pakhmanova, O.A., Petrol. Chem., 2011, vol. 51, pp. 32–38. https://doi.org/10.1134/S0965544111010087
Dehaghani, A.H.S. and Pirouzfar, V., Petrol. Chem., 2018, vol. 58, no. 8, pp. 702–708. https://doi.org/10.1134/S0965544118080042
Saleh, S., Pirouzfar, V., and Alihosseini, A., J. Therm. Anal. Calorim., 2019, vol. 136, no. 4, pp. 1817–1830. https://doi.org/10.1007/s10973-018-7809-3
Kianfar, E., Salimi, M., Pirouzfar, V., and Koohestani, B., Int. J. Chem. React. Eng., 2018, vol. 16, no. 7, p. 20170229. https://doi.org/10.1515/ijcre-2017-0229
Kianfar, E., Salimi, M., Pirouzfar, V., and Koohestani, B., Int. J. Appl. Ceram. Technol., 2018, vol. 15, pp. 734–741. https://doi.org/10.1111/ijac.12830
Pirouzfar, V. and Omidkhah, M., Iran. Polym. J., 2016, vol. 25, no. 3, pp. 203–212. https://doi.org/10.1007/s13726-016-0414-z
Kianfar, E., Pirouzfar, V., and Sakhaeinia, H., J. Taiwan Inst. Chem. Eng., 2017, vol. 80, pp. 954–962. https://doi.org/10.1016/j.jtice.2017.08.017
Salimi, M., Pirouzfar, V., and Kianfar, E., Polym. Sci. Ser. A, 2017, vol. 59, no. 4, pp. 566–574. https://doi.org/10.1134/S0965545X17040071
Soleymanipour, S.F., Dehaghani, A.H.S., Pirouzfar, V., and Alihosseini, A., J. Appl. Polym. Sci., 2016, vol. 133, no. 34. https://doi.org/10.1002/app.43839
Heydari, S. and Pirouzfar, V., RSC Adv., 2016, vol. 6, no. 17, pp. 14149–14163. https://doi.org/10.1039/C5RA27772H
Pirouzfar, V., Moghaddam, A.Z., and Mirza, B., J. Energy Resour. Technol., 2012, vol. 134, no. 4, pp. 041101/1–041101/6. https://doi.org/10.1115/1.4007483
Zamankhan, F., Pirouzfar, V., Ommi, F., and Valihesari, M., Environ. Sci. Pollut. Res., 2018, vol. 25, pp. 22889–22902. https://doi.org/10.1007/s11356-018-2066-3
Valihesari, M., Pirouzfar, V., Ommi, F., and Zamankhan, F., Fuel, 2019, vol. 254, p. 115618. https://doi.org/10.1016/j.fuel.2019.115618
Hashemzehi, M., Pirouzfar, V., Nayebzadeh, H., and Alihosseini, A., Fuel, 2020, vol. 263, p. 116422. https://doi.org/10.1016/j.fuel.2019.116422
Hashemzehi, M., Pirouzfar, V., Nayebzadeh, H., and Alihosseini, A., Adv. Powder Technol., 2020, vol. 31, no. 4, pp. 1470–1479. https://doi.org/10.1016/j.apt.2020.01.010
Dehaghani, A.H.S. and Pirouzfar, V., Chem. Eng. Technol., 2017, vol. 40, pp. 1693–1701. https://doi.org/10.1002/ceat.201600693
Luckenbach, E.C., Worley, A.C., Reichle, A.D., and Gladrow, E.M., Petroleum Processing Handbook, McKetta, J.J., Ed., New York, Marcel Dekker Inc., 1992, p. 349.
Sadeghbeigi, R., Fluid Catalytic Cracking: Design, Operation, and Troubleshooting of FCC Facilities, Houston: Gulf Publishing Company, TX, 1995.
O’Connor, P., Hydrocarbon Processing, Int. Ed., 1991, vol. 70, no. 11, pp. 76–84.
Gary, J.H. and Handwerk, G.E., Petroleum Refining Technology and Economics, New York: Marcel Dekker, Inc., 2001, 4th ed.
Nelson, W.L., Petroleum Refinery Engineering, New York: McGraw–Hill Book Co., 1958, 4th ed., pp. 759–810.
Bradley, S.A., Gattuso, M.J., and Bertolacini, R.J., Characterization and Catalyst Development. Symposium Series, no. 411, American Chemical Society, Washington, DC, 1989.
AL-Khattaf, S. and de Lasa, H.I., Ind. Eng. Chem. Res., 2001, vol. 40, pp. 5398–5404. https://doi.org/10.1021/ie001141c
Germain, J.E., Catalytic Conversion of Hydrocarbons, New York: Academic Press, Inc., 1969.
Jones, D.S.J. and Pujado, P.P., Handbook of Petroleum Processing, The Netherlands: Springer, 2006, 1st ed.
U.S. Downstream Processing of Fresh Feed Input by Catalytic Cracking Units, Energy Information Administration, U.S. Dept. of Energy, 2012.
Choudary, N.V. and Newalkar, B.L., J. Porous Mater., 2011, vol. 18, pp. 685–692. https://doi.org/10.1007/s10934-010-9427-8
Panariti, N., Del Bianco, A., Del Piero, G., and Marchionna, M., Appl. Catal. A: Gen., 2000, vol. 204, pp. 203–213. https://doi.org/10.1016/S0926-860X(00)00531-7
Blazek, J.J. and Davidson, C., Hydrocarbon Proc., 1981, vol. 63, pp. 2–10.
Gupta, A., Subba, R., and Rao, D., Chem. Eng. Sci., 2003, vol. 58, pp. 4567–4579. https://doi.org/10.1016/S0009-2509(03)00341-5
Cerqueiraa, H.S., Caeirob, G., Costac, L., and Ramôa Ribeiro, F., J. Mol. Catal. A. Chem., 2008, vol. 292, pp. 1–13. https://doi.org/10.1016/j.molcata.2008.06.014
Magee, J.S. and Mitchell, M.M., Fluid Catalytic Cracking: Science and Technology, New York: Elsevier, 1993, vol. 76, 1st ed.
AL-Khattaf, S. and de Lasa, H.I., Ind. Eng. Chem. Res., 1999, vol. 38, pp. 1350–1356. https://doi.org/10.1021/ie980433z
AL-Khattaf, S. and de Lasa, H.I., Can. J. Chem., 2001, vol. 79, pp. 341–348. https://doi.org/10.1002/cjce.5450790306
Al-Khattaf, S., Appl. Catal. A: Gen., 2002, vol. 231, pp. 293–306. https://doi.org/10.1016/S0926-860X(02)00071-6
Ali, H., Rohani, S., and Corriou, J.P., Chem. Eng Res. Des., 1997, vol. 75, pp. 401–412. https://doi.org/10.1205/026387697523868
Gillis, D., Wees, M.V., and Zimmerman, P., Upgrading Residues to Maximize Distillate Yields, UOP LLC, A Honeywell Company, Des Plaines, Illinois, U.S.A., 2007.
Pradhan, K., BTech Thesis, Odisha, 2012.
Sahu, J., Mahalik, K., Nam, H.K., Ling, T.Y., Woon, T.S., Rahman, M.S.B.A., Mohanty, Y., Jayakumar, N., and Jamuar, S., Environ. Prog. Sustain. Energy, 2014, vol. 33, pp. 298–307. https://doi.org/10.1002/ep.11748
Popa, C., Procedia Eng., 2015, vol. 100, pp. 602–608. https://doi.org/10.1016/j.proeng.2015.01.410
Popa, C., Procedia Eng., 2014, vol. 89, pp. 1469–1474. https://doi.org/10.1016/j.proeng.2014.03.143
Gupta, R.K., Kumar, V., and Srivastava, V.K., Chem. Eng. Sci., 2007, vol. 62, pp. 4510–4528. https://doi.org/10.1016/j.ces.2007.05.009
Speight, J.G., Ann. Rev. Energy, 1986, vol. 11, pp. 253–274. https://doi.org/10.1146/annurev.eg.11.110186.001345
Gatte, R.R., Harding, R.H., Albro, T.G., Chin, D.S., and Wormsbecher, R.F., ACS Preprints, 1992, vol. 137, no. 1, pp. 33–40.
Author information
Authors and Affiliations
Corresponding authors
Ethics declarations
The authors declare no conflict of interest requiring disclosure in this article.
Additional information
Translated from Neftekhimiya, 2021, Vol. 61, No. 4, pp. 483–493 https://doi.org/10.31857/S0028242121040043.
Rights and permissions
About this article
Cite this article
Aregawi, B.H., Atiku, F.A., Pirouzfar, V. et al. Evaluating the Optimal Capacity for the Implementation of Fluidized Catalytic Cracking in the Refinery by the Technical and Economic Analysis. Pet. Chem. 61, 729–738 (2021). https://doi.org/10.1134/S096554412107001X
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1134/S096554412107001X