Unplanned process shutdowns can cost a refinery over seven figures per day. It's crucial to stay within process limits and stabilize operations swiftly when disturbances occur. CCC’s advanced algorithms, honed through years of application-specific experience, help minimize process upsets and safely restore normal operations.
Challenges in Refinery Operations
The success of a refinery hinges on system availability and reliability. Shutdowns can result from trips in critical equipment such as wet gas compressors or main air blowers on fluidized catalytic cracker units. Trips in hydrogen recycle compressors for catalytic reformers can also lead to significant production losses.
Key Challenges:
Wet gas compressors face significant changes in inlet gas composition and require precise pressure control.
Stringent environmental regulations impose strict requirements on flaring.
CCC's Advanced Solutions
Minimize Process Trips:
CCC's advanced control solutions are specifically designed for FCCU optimization. Process stability is significantly improved through:
Regenerator airflow control
Wet gas compressor throughput
Fractionator/regenerator differential pressure control
Robust differential pressure control reduces the likelihood of catalyst flow reversals and costly catalyst releases.
Increase Production:
Precise pressure control in the fractionator overhead receiver keeps your wet gas compressor within vacuum and flare setpoints. Lowering overhead receiver pressure decreases regenerator pressure, increasing mass flow and catalyst regeneration, thereby boosting production.
Flare-less Start-ups:
CCC antisurge and performance algorithms enhance start-up automation, eliminating wet gas flaring.
Comprehensive Refinery Control:
CCC provides control solutions for a wide range of refinery applications, including:
Fluid Catalytic Cracking Unit:
Power Recovery Train
Expander
Air Blower
Motor-Generator
Steam Turbine
Wet Gas Compressor
Residual Catalytic Cracking Unit
Delayed Coker
Reformer Units
Alkylation Units
Lube Oil Units
Instrument Air Systems
Tangible Results
Preventing one day of unplanned shutdown can save you $2 million in lost revenue. CCC's automated start-up can bring your FCCU online up to 12 hours faster while eliminating wet gas flaring entirely.
Key Benefits:
Reduce plant shutdowns
Improve plant efficiency
Minimize risk of costly environmental fines
Limit wasted energy due to recycling
Minimize flaring
Decrease start-up time
Reduce noise and light pollution
Invest in CCC’s advanced control solutions to enhance refinery operations, maximize efficiency, and minimize losses.
