Knowledge Base /
Industry Applications, Petroleum Refining
Mimic Dynamic Simulation for Fluidized Catalytic Crackers
By Hannah Jokisch
Product: Mimic Simulation

Mimic dynamic simulation application package for fluidized catalytic crackers provides a high performance solution for operator training and control system optimization.

The virtual fluidized catalytic cracker package provides the complete environment for control system optimization and is an effective tool for teaching process and control engineers the control and operation of the fluidized catalytic cracker (FCC).

Fluidized Bed Catalytic Crackers are the heart of many refineries, essential to the production of high octane gasoline.

Mimic Dynamic Simulation allows refinery operation managers to:

  • Train operators on infrequent and dangerous process occurrences
  • Properly prepare an inexperienced operator workforce and create a smooth knowledge transfer process
  • Practice smooth operation of the process
  • Test control system enhancements
  • Increase overall plant safety

This package uses Mimic Advanced Modeling Objects for dynamic, real-time, first principles modeling. The Mimic Advanced Modeling Objects are part of the Mimic Advanced Modeling Objects License that adds sophisticated modeling objects into the Mimic Simulation Studio modeling palette. These Objects can be used on Mimic systems for application software testing or operator training. The Mimic Advanced Modeling Objects License provides:

  • Medium to High Fidelity Simulation Performance
  • Rigorous First Principles process modeling using proven dynamic, real-time modeling methods
  • Modeling objects based on Unit Operations
  • Block to block communications of all parameters with one connection using Mimic Streams
  • Easy handling of individual stream component physical properties using Mimic Component Sets
  • Mimic OTM Process Snapshot support
  • Mimic OPC Server Access to all model parameters
  • Mimic OPC Bridge Communication with external Control Systems

Fluidized Catalytic Cracker Dynamic Simulation

Mimic Dynamic Simulation for a fluidized catalytic cracker provides accurate, real-time I/O updates to the off-line control system. The simulation consists of a collection of real-time, dynamic, first principles unit operation models configured to respond closely to the actual operations of the user’s facility. The MYNAH application package for fluidized catalytic cracker includes dynamic models of the following unit operations:

  • Riser reactor with spent catalyst separation cyclones
  • Catalyst regeneration with cyclones
  • Combustion air blower
  • Customized valve characteristics to match actual plant controls
  • Optional torch oil addition to maintain catalyst temperature

Riser Reactor

The reactor is rigorously modeled using stacked Mimic’s Advanced Modeling Reactor Objects. Included in this model are the following capabilities:

  • Dynamic real time mass and energy balances
  • Vaporization of the feed
  • Cracking of hydrocarbons by reaction using the catalyst
  • Coke production on the catalyst in the riser
  • Spent catalyst separation from the product stream

Reactor Model in Mimic Simulation Studio

Catalytic RegeneratorThe catalyst regenerator is thoroughly modeled using Mimic’s Advanced Modeling Reactor and vessel objects. The capabilities of this part of the process include:

  • Dynamic real time mass and energy balance
  • Burning coke off of the catalyst
  • Combustion air feed via a blower
  • Separation of flue from the catalyst
  • Optional torch oil feed as needed to maintain catalyst temperature
Regenerator Model in Mimic Simulation Studio

The Trainer Experience

Instructor controls in Mimic and instructor screens in Mimic Component Studio allow your training team to prepare for working with the control system and process in the real plant. Any element in Mimic can be manipulated or controlled, instructor screens provide easy access in one location. Typical instructor controls provided on instructor screens include:

  • Controls to manipulate operating conditions such as boundary conditions and compositions.
  • Utility quality and availability controls.
  • Snapshot restore controls to restore to steady-state operation.
  • Training Scenario controls.
  • Ad-hoc device failure FCCU Instructor Station Graphic in Mimic Component Studio.
FCC Instructor Station graphic in Mimic Component Studio

Mimic Dynamic Simulation Application Packages

Mimic Dynamic Simulation Application Packages provide an excellent return on investment for plants training and operation budgets. Unlike other dynamic simulation technologies, they are:

  • Built for Operator Training and Control System Optimization. Because the dynamic simulation is built using Mimic Simulation Software, it fully supports operator training and configuration testing with any process control system environment. Mimic Simulated IO Drivers are non-intrusive and high performance, allowing IO simulation of any open process control system.
  • Easy to Customize and Modify. Mimic Operator Training Packages use Mimic Simulation Software Advanced Modeling Objects to deliver high-fidelity, dynamic process models. There is no hidden configuration in the solution. The user can easily modify the model to make it reflect the design of their plant design. The user can also add training scenarios and process snapshots as needed without limit.
  • Able to Work with Any Process Control System. Mimic models work directly with Mimic base level models and the Mimic Simulated IO System. This allows easy-to-maintain, accurate simulation of IO and control modules and provides real-time updates to the off-line control system.
  • Flexible, Powerful and Dynamic. The package is based upon Mimic Simulation Software; it is scalable from very small simulations to very large ones in the same software license. Mimic's multi-threaded simulation engine allows the fastest real-time performance of any simulation offering while still delivering accurate, dynamic simulations for a realistic operator experience at the control system operator station.
  • Scalable to Cloud Base Architecture. MYNAH Technologies is the industry leader in delivering cloud based dynamic simulation systems based upon VMWare Virtualization Technology. MYNAH's Virtual Dynamic Simulators offer breakthrough flexibility and performance unavailable in legacy simulation architectures.
MYNAH’s Virtual Dynamic Simulator brings the benefits of Cloud Based Computing to operator training systems

The virtual fluid catalytic cracker package is an excellent platform for refinery operations managers to optimize their automation platform and address their operator training needs. Mimic Simulation Software is an enabling technology that addresses the needs of the energy industry process operators (see the Business Case for the Virtual Plant).

Ordering Information:

For a quotation or more information on Mimic Dynamic Simulation for Fluidized Catalytic Crackers, contact MYNAH Technologies at +1.636.728.2000 or