Simulation of Fluid Catalytic Cracking Unit for Optimum Production of Gasoline Using Aspen HYSYS

Document Type : Research Paper

Authors

Department of Chemical Engineering, Faculty of Engineering, Rivers State University, Port Harcourt, Nigeria.

Abstract

This study presents the steady-state behavior of the Fluid Catalytic Cracking of Vacuum Gas Oil in an existing industrial Unit. The riser and regenerator reactors, coupled with the main fractionator, were simulated using Aspen HYSYS software with a 21-lump kinetic model that accounts for catalytic cracking kinetics and heat balance within the unit. Model predictions for the product species showed good agreement with the industrial plant data at the same operating conditions, with a percentage deviation ranging from 1.13% to 16.85%. Simulation results indicate that the Riser Outlet Temperature (ROT) and feed flow rate have significant effects on the performance of the riser and regenerator reactors. Sensitivity analysis performed on the reactor gave the following optimum values: To increase the total yield of Gasoline and Diesel, an ROT within the interval of 510-515°C should be selected; for an increase in the total yield of Gasoline and LPG, an ROT in the range 524-535°C is recommended; An ROT of 530°C should be used when increasing unit throughput to maximize gasoline output.

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Main Subjects

References

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Journal of Chemical and Petroleum Engineering
Volume 59, Issue 2
December 2025
Pages 225-236

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History

  • Receive Date: 13 April 2024
  • Revise Date: 25 March 2025
  • Accept Date: 19 April 2025

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