DETECTION OF CATALYST LOSSES IN A FLUID CATALYTIC CRACKER FOR USE IN ABNORMAL SITUATION PREVENTION
First Claim
Patent Images
1. A method of detecting catalyst loss in a fluid catalytic cracker comprising:
- measuring a differential pressure across a cyclone in a fluid catalytic cracker;
determining an initial mean differential pressure across the cyclone during a first period of operation of the fluid catalytic cracker;
monitoring a current mean differential pressure across the cyclone during a second period of operation of the fluid catalytic cracker; and
determining an abnormal catalyst loss event if the current mean differential pressure across the cyclone is lower than the initial mean differential pressure across the cyclone by more than a threshold.
1 Assignment
0 Petitions
Accused Products
Abstract
A method and system for detecting and/or predicting abnormal levels of catalyst loss in a fluid catalytic cracking unit. The method and system measures a differential pressure across portions of a fluid catalytic cracker, such as a reactor cyclone or a regenerator cyclone, and determines abnormal catalyst loss when the differential pressure changes significantly from a baseline differential pressure. The claimed method and system implements algorithms using computing devices to detect or predict an abnormal condition based on the change in a monitored differential pressure in a fluid catalytic cracking unit.
23 Citations
25 Claims
-
1. A method of detecting catalyst loss in a fluid catalytic cracker comprising:
-
measuring a differential pressure across a cyclone in a fluid catalytic cracker; determining an initial mean differential pressure across the cyclone during a first period of operation of the fluid catalytic cracker; monitoring a current mean differential pressure across the cyclone during a second period of operation of the fluid catalytic cracker; and determining an abnormal catalyst loss event if the current mean differential pressure across the cyclone is lower than the initial mean differential pressure across the cyclone by more than a threshold. - View Dependent Claims (2, 3, 4, 5)
-
-
6. A method of detecting catalyst loss in a fluid catalytic cracking unit comprising:
-
monitoring a differential pressure across a cyclone in a fluid catalytic cracker; monitoring a set of process parameters that effect the differential pressure across the cyclone; generating a regression model during a learning period based on the monitored differential pressure and a collected set of monitored process parameters affecting the differential pressure across the cyclone; calculating a predicted differential pressure using the regression model; determining an abnormal catalyst loss event if a current differential pressure across the cyclone is different than the predicted pressure differential across the cyclone by more than a threshold. - View Dependent Claims (7, 8, 9, 10)
-
-
11. A device for detecting abnormal catalyst loss in a fluid catalytic cracking unit comprising:
-
a set of sensors for periodically measuring a pressure differential across a cyclone in the fluid catalytic cracking unit; a logic module that determines a set of statistical parameters of the periodically measured pressure differential over a period of time; a rules module that stores a set of instructions; a training module that stores a set of process parameters; a calculation module that determines an abnormal catalyst loss event based on the set of instructions in the rules module and the set of process parameters in the training module, wherein the calculation module generates an indication when an abnormal catalyst loss event occurs. - View Dependent Claims (12, 13, 14, 15, 16)
-
-
17. A device for detecting abnormal catalyst loss in a fluid catalytic cracking unit comprising:
-
a first input for receiving data on a pressure differential across a cyclone in the fluid catalytic cracking unit; a second input for receiving data on a set of process parameters affecting the pressure differential; a model implementation unit for calculating a predicted pressure differential value based on the set of process parameters; a deviation detector that compares the predicted pressure differential value to an actual pressure differential value and generates a signal when the difference between the predicted pressure differential value and the actual pressure differential value exceeds a threshold. - View Dependent Claims (18, 19, 20)
-
-
21. A system for detecting abnormal catalyst loss in a fluid catalytic cracking unit comprising:
-
a process control system including a workstation, a process controller, and a plurality of field devices, wherein the workstation, process controller, and the plurality of field devices are communicatively connected to each other; a fluid catalytic cracking unit having a reactor cyclone and a regenerator cyclone, wherein at least one field device is adapted to measure a pressure differential across the reactor cyclone or the regenerator cyclone; an abnormal operation detection device adapted to receive data on the measured pressure differential, to access a set of normal operating values for the pressure differential, and to generate an alert when a difference between a measured pressure differential and the set of normal operating values exceeds a threshold. - View Dependent Claims (22, 23, 24, 25)
-
Specification