Presentation from downstream track at KBC Europe Software User Conference June 2018

1. Proprietary Information of Albemarle Corporation.
How Can I Use FCC-SIM
to Monitor My
FCC Unit Regularly?
Alan Kramer
Global FCC Modeling Specialist
KBC Software User Group Conference
2018
London

2. Proprietary Information of Albemarle Corporation.
The Questions
2
•What are the important calibration
factors?
•How does catalyst affect calibration
factors?
•How can I tell if my calibration factors
are any good?
•How should I select which cases’
calibration factors to use?
Calibration
•How can I tell if I need to manually
tune the model?
•How do I know what factor to adjust?
Tuning

3. Proprietary Information of Albemarle Corporation.
The Questions
3
•What are the important calibration
factors?
•How does catalyst affect calibration
factors?
•How can I tell if my calibration factors
are any good?
•How should I select which cases’
calibration factors to use?
Calibration
•How can I tell if I need to manually
tune the model?
•How do I know what factor to adjust?
Tuning

4. Proprietary Information of Albemarle Corporation.
What are the important
calibration factors?

5. Proprietary Information of Albemarle Corporation.
• Important equations inside FCC-SIM
– Rate of coking
– Rate of cracking
– Rate of C1-C4 gas production
What are the Important Calibration Factors?
5
𝑟𝑐𝑟𝑎𝑐𝑘 = 𝑟𝑥 𝑐𝑜𝑛𝑠𝑡 • 𝑐𝑎𝑟𝑏𝑜𝑛 • 𝐶/𝑂 • 𝑡𝑒𝑚𝑝 • 𝑎𝑐𝑡𝑖𝑣𝑖𝑡𝑦 • 𝑓𝑒𝑒𝑑 • 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒
𝑟𝑔𝑎𝑠 = 𝑟𝑥 𝑐𝑜𝑛𝑠𝑡 • 𝑡𝑒𝑚𝑝 • 𝑎𝑐𝑡𝑖𝑣𝑖𝑡𝑦 • 𝑓𝑒𝑒𝑑 • 𝑟𝑐𝑟𝑎𝑐𝑘
𝑟𝑐𝑜𝑘𝑒 = 𝑟𝑥 𝑐𝑜𝑛𝑠𝑡 • 𝑐𝑎𝑟𝑏𝑜𝑛 • 𝑡𝑖𝑚𝑒 • 𝑡𝑒𝑚𝑝 • 𝑎𝑐𝑡𝑖𝑣𝑖𝑡𝑦 • 𝑓𝑒𝑒𝑑 • 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒

6. Proprietary Information of Albemarle Corporation.
• Important equations inside FCC-SIM
– Rate of coking
– Rate of cracking
– Rate of C1-C4 gas production
What are the Important Calibration Factors?
𝑟𝑐𝑟𝑎𝑐𝑘 = 𝑟𝑥 𝑐𝑜𝑛𝑠𝑡 • 𝑐𝑎𝑟𝑏𝑜𝑛 • 𝐶/𝑂 • 𝑡𝑒𝑚𝑝 • 𝑎𝑐𝑡𝑖𝑣𝑖𝑡𝑦 • 𝑓𝑒𝑒𝑑 • 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒
𝑟𝑔𝑎𝑠 = 𝑟𝑥 𝑐𝑜𝑛𝑠𝑡 • 𝑡𝑒𝑚𝑝 • 𝑎𝑐𝑡𝑖𝑣𝑖𝑡𝑦 • 𝑓𝑒𝑒𝑑 • 𝑟𝑐𝑟𝑎𝑐𝑘
𝑟𝑐𝑜𝑘𝑒 = 𝑟𝑥 𝑐𝑜𝑛𝑠𝑡 • 𝑐𝑎𝑟𝑏𝑜𝑛 • 𝑡𝑖𝑚𝑒 • 𝑡𝑒𝑚𝑝 • 𝑎𝑐𝑡𝑖𝑣𝑖𝑡𝑦 • 𝑓𝑒𝑒𝑑 • 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒𝑥𝑘𝑢𝑝7
Kinetic Coke Make
𝑥𝑘𝑢𝑝9
Conversion
Kinetic
𝑥𝑘𝑢𝑝14
Wet Gas Yield

7. Proprietary Information of Albemarle Corporation.
• Important equations inside FCC-SIM
– Rate of coking
– Rate of cracking
– Rate of C1-C4 gas production
What are the Important Calibration Factors?
7
𝑟𝑐𝑟𝑎𝑐𝑘 = 𝑟𝑥 𝑐𝑜𝑛𝑠𝑡 • 𝑐𝑎𝑟𝑏𝑜𝑛 • 𝐶/𝑂 • 𝑡𝑒𝑚𝑝 • 𝑎𝑐𝑡𝑖𝑣𝑖𝑡𝑦 • 𝑓𝑒𝑒𝑑 • 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒
𝑟𝑔𝑎𝑠 = 𝑟𝑥 𝑐𝑜𝑛𝑠𝑡 • 𝑡𝑒𝑚𝑝 • 𝑎𝑐𝑡𝑖𝑣𝑖𝑡𝑦 • 𝑓𝑒𝑒𝑑 • 𝑟𝑐𝑟𝑎𝑐𝑘
𝑟𝑐𝑜𝑘𝑒 = 𝑟𝑥 𝑐𝑜𝑛𝑠𝑡 • 𝑐𝑎𝑟𝑏𝑜𝑛 • 𝑡𝑖𝑚𝑒 • 𝑡𝑒𝑚𝑝 • 𝑎𝑐𝑡𝑖𝑣𝑖𝑡𝑦 • 𝑓𝑒𝑒𝑑 • 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒𝑥𝑘𝑢𝑝7
Kinetic Coke Make
𝑥𝑘𝑢𝑝179
Hydrothermal
Deactivation
𝑥𝑘𝑢𝑝13
Contaminant
Coke Factor
𝑥𝑘𝑢𝑝9
Conversion
Kinetic
𝑥𝑘𝑢𝑝22
Reaction Rate
Distribution
𝑥𝑘𝑢𝑝179
Hydrothermal
Deactivation
𝑥𝑘𝑢𝑝13
Contaminant
Coke Factor
𝑥𝑘𝑢𝑝179
Hydrothermal
Deactivation
𝑥𝑘𝑢𝑝13
Contaminant
Coke Factor
𝑥𝑘𝑢𝑝9
Conversion
Kinetic
𝑥𝑘𝑢𝑝22
Reaction Rate
Distribution
𝑥𝑘𝑢𝑝14
Wet Gas Yield

8. Proprietary Information of Albemarle Corporation.
Important Calibration Factors
Calibration Factor Factor Pertains To…
7 Kinetic Coke Make Regenerator Temperature
13 Contaminant Coke Factor Hydrogen, Contaminant & Catalytic Coke
9 Conversion Kinetic Conversion
14 C1-C4 Gas Yield Catalytically Cracked Light Gasses
22 Reaction Rate Distribution LCO/Bottoms Ratio
179 Hydrothermal Deactivation Catalyst Addition Rate & Ecat Activity
8

9. Proprietary Information of Albemarle Corporation.
Important Calibration Factors
Calibration Factor Factor Pertains To…
7 Kinetic Coke Make Regenerator Temperature
13 Contaminant Coke Factor Hydrogen, Contaminant & Catalytic Coke
9 Conversion Kinetic Conversion
14 C1-C4 Gas Yield Catalytically Cracked Light Gasses
22 Reaction Rate Distribution LCO/Bottoms Ratio
179 Hydrothermal Deactivation Catalyst Addition Rate & Ecat Activity
11 Heat of Cracking Ratio Heat Balance Quality / Consistency of Data
1 / 93 Regen Coke Burn Rate C  CO in Regenerator (dense bed)
2 / 94 Regen CO/CO2 Rate CO  CO2 in Regenerator (dilute bed)
15-21
190-3
C2-C4 Individual Gas Yields Individual Gas Yield Selectivities
9

10. Proprietary Information of Albemarle Corporation.
Important Calibration Factors
Calibration Factor Factor Pertains To… Affected by Cat Formulation?
7 Kinetic Coke Make Regenerator Temperature Yes
13 Contaminant Coke Factor Hydrogen, Contaminant & Catalytic Coke Yes
9 Conversion Kinetic Conversion Yes
14 C1-C4 Gas Yield Catalytically Cracked Light Gasses Yes
22 Reaction Rate Distribution LCO/Bottoms Ratio Yes
179 Hydrothermal Deactivation Catalyst Addition Rate & Ecat Activity Yes
11 Heat of Cracking Ratio Heat Balance Quality / Consistency of Data Yes
1 / 93 Regen Coke Burn Rate C  CO in Regenerator (dense bed) No*
2 / 94 Regen CO/CO2 Rate CO  CO2 in Regenerator (dilute bed) No*
15-21
190-3
C2-C4 Individual Gas Yields Individual Gas Yield Selectivities Yes
10
* Yes for combustion promoter

11. Proprietary Information of Albemarle Corporation.
Important Calibration Factors
Calibration Factor
Affected by Cat
Formulation?
How Catalyst Affects this Factor
7 Kinetic Coke Make Yes Coke selectivity of base catalyst
13 Contaminant Coke Factor Yes Metals (Nickel) passivation technologies; ADM-60
9 Conversion Kinetic Yes Activity / CTO
14 C1-C4 Gas Yield Yes ZSM-5 Usage, Bottoms Cracking
22 Reaction Rate Distribution Yes Bottoms Cracking / High Matrix; ADM-20; ADM-30
179 Hydrothermal Deactivation Yes RE/Z, Other Stabilizers; Z/M; Binding Technology; GRANITETM
11 Heat of Cracking Ratio Yes Rare earth on zeolite
1 / 93 Regen Coke Burn Rate No* Extreme overpromoting or underpromoting
2 / 94 Regen CO/CO2 Rate No* Extreme overpromoting or underpromoting
15-21
190-3
C2-C4 Individual Gas Yields Yes Re/Z; ACTIONTM; ZSM-5 Usage
11
* Yes for combustion promoter

12. Proprietary Information of Albemarle Corporation.
Important Calibration Factors
Calibration Factor Factor Pertains To…
Affected by Cat
Formulation?
Typical
Value
7 Kinetic Coke Make Regenerator Temperature Yes 0.1
13 Contaminant Coke Factor Hydrogen, Contaminant & Catalytic Coke Yes 1.0
9 Conversion Kinetic Conversion Yes 1.0
14 C1-C4 Gas Yield Catalytically Cracked Light Gasses Yes 1.0
22 Reaction Rate Distribution LCO/Bottoms Ratio Yes 1.0
179 Hydrothermal Deactivation Catalyst Addition Rate & Ecat Activity Yes -
11 Heat of Cracking Ratio Heat Balance Quality / Consistency of Data Yes 1.0
1 / 93 Regen Coke Burn Rate C  CO in Regenerator (dense bed) No* 1.0
2 / 94 Regen CO/CO2 Rate CO  CO2 in Regenerator (dilute bed) No* 1.0
15-21
190-3
C2-C4 Individual Gas Yields Individual Gas Yield Selectivities Yes -
12
* Yes for combustion promoter

13. Proprietary Information of Albemarle Corporation.
Are my calibration factors
good?

14. Proprietary Information of Albemarle Corporation.
Are My Calibration Factors Any Good?
14
• Correlate back to calibration input data
• Correct data or eliminate case
• Check for coincidence with catalyst change
• Correlate back to calibration input data
• Theoretically these should be flat with little variation
• Correlate back to calibration input data
• Use best judgment on input data

15. Proprietary Information of Albemarle Corporation.
Variability in Calibration Factors
15

16. Proprietary Information of Albemarle Corporation.
Variability in Calibration Factors
16

17. Proprietary Information of Albemarle Corporation.
Calibration Factor Trendplots – Flyers Example #1
17

18. Proprietary Information of Albemarle Corporation.
Calibration Factor Trendplots – Flyers Example #1
18
CORREL function vs Calibration Input Rows
=ABS(CORREL(range1,range2))

19. Proprietary Information of Albemarle Corporation.
Calibration Factor Trendplots – Flyers Example #1
19

20. Proprietary Information of Albemarle Corporation.
Calibration Factor Trendplots – Flyers Example #2
20

21. Proprietary Information of Albemarle Corporation.
Calibration Factor Trendplots – Flyers Example #2
21

22. Proprietary Information of Albemarle Corporation.
What calibration cases
should I use?

23. Proprietary Information of Albemarle Corporation.
Which Calibration Cases to Use?
23

24. Proprietary Information of Albemarle Corporation.
Which Calibration Cases to Use?
24

25. Proprietary Information of Albemarle Corporation.
Which Calibration Cases to Use?
25
•As many as possible
•Always consider catalyst formulation
•Averaging calibration factors
dampens variation effects
•Superday / single-day use may
amplify variations
Which Cases Should I Use?
•Significantly different feed rate
•Different combustion mode
•Catalyst transition
•Different catalyst
Which cases should I avoid?

26. Proprietary Information of Albemarle Corporation.
Superday vs. Average Projection
26
• FCC-SIM Experiment
• 22 cases (weekly averages)
• Questionable daily data removed
1. Calibrate model for all 22 cases
2. Predict 22 cases
» Independent variables = same for all, average for all 22 cases
» Calibration factors = each cases’ individual
3. Predict 1 more case
» Independent variables = same as above, average for all 22 cases
» Calibration factors = average for all 22 cases
4. Analyze the variability in the predicted yields

27. Proprietary Information of Albemarle Corporation.
Superday vs. Average Projection
27
Wt% Yield Ranges Predicted with Case Calibration Factors
Yield, wt% Min -1 sigma Average
Calibration
Factors
+1 sigma Max
H2 0.1 0.10 0.12 0.13 0.15
Dry Gas 2.12 2.23 2.36 2.50 2.64
LPG 16.55 17.30 18.14 18.98 19.73
C5 – 430F
C5 – 221C
47.06 47.97 49.19 50.41 51.77
430-650F
221-343C
14.61 15.80 16.64 17.48 17.87
650F+
343C+
5.11 5.86 6.5 7.14 7.55
Regen Temp F
Regen Temp C
1270
688
1296
703
1313
712
1330
721
1336
724

28. Proprietary Information of Albemarle Corporation.
Superday vs. Average Projection
28
Delta wt% From Yields Predicted with Average Calibration Factors
Yield, wt% Min -1 sigma Average
Calibration
Factors
+1 sigma Max
H2 -0.02 -0.014 0.014 0.03
Dry Gas -0.24 -0.13 0.13 0.28
LPG -1.59 -0.84 0.84 1.59
C5 – 430F
C5 – 221C
-2.13 -1.22 1.22 2.58
430-650F
221-343C
-2.03 -0.84 0.84 1.23
650F+
343C+
-1.39 -0.64 0.64 1.05
Regen Temp F
Regen Temp C
-43F
-24C
-17F
-9C
17F
9C
23
13C

29. Proprietary Information of Albemarle Corporation.
Calibration Summary
• Focus on the key calibration factors.
• Trendplot key calibration factors always after calibrating.
• Calibration factor trendplots should be flat over time.
• Fix flyers & variability. Understand the reason for trends.
• Use the CORREL function to help relate calibration factors to calibration inputs.
• When choosing calibration cases to average:
– Use as many as possible.
– Consider the base catalyst, feed rate, combustion mode.
• Don’t use superdays.
29

30. Proprietary Information of Albemarle Corporation.
Revisit The Questions
30
•What are the important calibration
factors?
•How does catalyst affect calibration
factors?
•How can I tell if my calibration factors
are any good?
•How should I select which cases’
calibration factors to use?
Calibration
•How can I tell if I need to manually
tune the model?
•How do I know what factor to adjust?
Tuning

31. Proprietary Information of Albemarle Corporation.