Automation and control of energy efficient fluid catalytic cracking processes for maximizing value a

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Petroleum oil is catalytically cracked by contacting oil with catalyst mixture consisting of a base cracking catalyst containing an stable Y-type zeolite and small amounts of rare-earth metal oxide, and an additive containing a shape-selective zeolite, in an FCC apparatus having a regeneration zone, a separation zone, and a stripping zone. Production of light-fraction olefins is maximized by applying appropriate process control, monitoring, and optimizing systems. Mathematical process models, including neural networks, statistical models and finite impulse models are used in conjunction with advanced controllers and optimizing routines to calculate optimal settings for various parameters. Process model and historical data to test a predictive system can provide early warning of potential performance degradation and equipment failure in the FCC unit, decreasing overall operating costs and increasing plant safety.