ENV-03-128 Selective Catalytic Reduction of NOx From Fluid Catalytic Cracking Case Study: BP Whiting Refinery

Description:

One of the newest examples of selective catalytic reduction (SCR) in service on a fluid catalytic cracking unit (FCCU) is scheduled to begin operation in October 2003 at the BP Products North America Inc. (BP) refinery in Whiting, Indiana. This application is a step beyond the typical refinery boiler/heater/furnace case since treatment of nitrogen oxides (NOx) in the regenerator flue gas must account for the other atmospheric contaminants generated simultaneously in the FCCU process. Such conditions typically include a high particulate loading. One must also be constantly aware of the possibility of process upsets. This paper presents a case study that relies upon the experience gained and lessons learned from numerous prior FCCU installations dating back to 1986. That experience has contributed in no small degree to the design and anticipated start-up of the present unit. Following a brief review of the FCCU process itself, the source of NOx in the process is discussed along with the origin and treatment in general of the other atmospheric contaminants. An extensive list of previous installations of this type by the SCR system supplier and the SCR catalyst manufacturer is provided, along with operational details from those cases. Successful performance as documented herein allows the owner/operator to meet regulatory requirements in a safe, reliable, and cost-effective manner. The design, start-up, and operation of the subject installation will add to that experience base.