FCC reactor in Aspen Hysys didn't converge. Even there is a match in material balance of the reactor . What can be a problem ? The used data are from existing FCC unit .
As steady state of continuous cracking process the reactor simulator must be a system of N algebraic non-linear equations. Such system can present convergence problems. I could recommend that your perform your mass balances for all the compounds in non-steady state and solve the differential equations from a given initial state until reach steady state, however I do not know if your software admits differential equations. If you can program your software with differential equations, you must consider that the system may have multiple steady-state solutions due to non-linear nature of equations. The final steady-state depends on initial conditions.