Optimizing Cracker Performance

• Heat transfer to process tubes
• Control of tube temperatures
• Pollutant (NOx) reduction
• Staged low-NOx burners would have flame roll-over
• Wall and floor burner placements
• Control process stream in tubes

• Sample Case - ABB Lummus Global used simulation to:
  • Model flow and reaction in process tubes to get accurate tube temperatures
  • Identify initial design flaws
  • Optimize changes in wall inlet angles and floor burner placement
  • New design is up and running, performing as advertised at end-user site

FCC Blower Optimization

• FCC performance is limited by blower performance
• Coke on FCC catalyst burned off in the regenerator
• The blower designed to draw air and supply it to the regenerator internal air blower manifold.
• Blower efficiency was below 90%
  • Significantly less than that of other similar units

• Sample Client Case Results and Benefits
  • Line from the ambient air inlet to the blower intake port simulated in search of flow distribution problems
  • Air flow through the line was strongly skewed by an unexpected interaction between two bends and the valve wafer in its normal open position
  • Flow concentrated on one side of the line at blower entrance, reducing efficiency
  • The equilibrium open position of the valve wafer could be adjusted.
  • Sidestepping of more expensive modifications
  • Potential for incremental capacity benefits exceeding $6 million/yr