Fluid Catalytic Cracking

Fluid Catalytic Cracking
Unsurpassed innovation, performance and reliability
Since 1990, KBR has designed more than a dozen FCC units and revamped more than 160 FCC units worldwide
Meeting Todays Challenges
Reners today face the choice of purchasing light sweet crudes at a premium price or investing in bottom-of-the-barrel upgrading. Yet with stringent environmental requirements and a dwindling supply of quality crudes, upgrading is the logical solution to remain competitive.
Frontrunner in FCC
Not only are we a recognized leader in FCC, but we also pioneered the technology in the late 1930s. This led to a KBR and ExxonMobil joint venture alliance in the design, construction and operation of the worlds rst commercial FCC unit at ExxonMobils Baton Rouge, Louisiana renery in 1942. It also marked the beginning of a solid partnership with ExxonMobil in FCC technology that remains today.
Renery ROI
Our FCC experts hold industry-leading experience in designing, engineering, procurement and construction services. We evaluate modications to increase capacity, improve and maximize product yield and enhance on-stream factor and mechanical reliability.
At the ExxonMobil FCC project in Altona, Australia, KBR proved that FCC solutions offer long term reliability and low capital costs.
Our experts can help clients:

Accelerate ROI, ROCE, RONA and cash ow Design, engineer, construct and service FCC units Increase protability Achieve cost objectives Reduce safety incidents Overcome resource constraints Identify new opportunities for improvement Revamp and replace technology Extend the life of FCC investment Sustain benets Stay current with environmental regulations
KBRs Technology Center (KBRTC) contains numerous pilot plants, analytical laboratories and pilot plant fabrication facilities and a talented staff of engineers, chemists, specialists and craftsmen who develop and commercialize new and improved process technologies.
Long-Term Reliability
Rigorous testing, ongoing research, catalyst evaluation, feedstock characteristics and product yield assessment make KBR a cut above. With KBR, our clients count on unmatched FCC solutions that are low in capital cost and high on quality, long-term reliability and operability.
Rigorous testing, ongoing research, catalyst evaluation, feedstock characteristics and product yield assessment make KBR a cut above.
Technical Services
Following start up of the unit as well as during normal operation, technical service engineers assist reners in gaining maximum value from investment in KBR technology through routine renery visits and consultation. We maximize clients ROI using our licensed technologies through technical services for operations and turnarounds.
Lower Capital Costs

Our joint engineering teams developed the KBR Orthoow FCC process technology, which includes the compact, self-supporting Orthoow converter and combines the disengager, stripper and regenerator vessels into a single vessel. This unique design minimizes the cost of construction, and also reduces the amount of eld mechanical work and required plot space.
KBR provides testing, training and process controls to help meet renery objectives
FCC Advanced Process Controls
KBRs Advanced Process Control (APC) is especially benecial for FCC units due to their complexities and large number of interactive variables. Our APC system consists of: Severity Control Combustion Control Pressure Balancing and Control Fractionator Control Vapor Recovery Unit (VRU) Control
APC gets you closer to targets and constraints, improves stability and makes operation seamless. This translates to enhanced operational information and faster responses to changes in renery objectives.
Operator Training Simulator

Successful start-up of grassroots FCC units is dependent on a well-trained operations team. To ensure your team is ready for anything, KBRs operator training simulator provides a realistic dynamic simulation of the FCC process congured to resemble the actual FCC operator interface.
KBRTC specializes in cold ow modeling the simulation of process characteristics at near ambient temperatures and pressures. Creating realistic cold ow models is a unique talent and KBR is a leading practitioner of this technique.
Advanced technology allows KBRs operators to simulate all aspects of plant operations and controls, as well as startups, shutdowns and emergencies.
Leading-edge technology and service that spans 100 years
Quick, Safe & Effective Revamps

KBRs approach to revamping draws upon unrivaled skill in all aspects of FCC technology. For fast-track implementation of the latest technology improvements, KBR and our industrial fabrication and construction partner, InServ, provide lump-sum turnkey revamp and turnaround solutions that include: Increased capacity and conversion Greater feedstock exibility Gasoline yield improvement Octane improvement Light olens yield optimization Closer integration with other renery operations Improvements in reliability, maintainability, environmental compliance and on-stream time
Design solutions. Optimize processes. Enhance productivity. Accelerate ROI.

Why Wait?
KBR turns visions into reality with our proven FCC technologies and advanced features from our alliance partner ExxonMobil. Together, we can design, construct and optimize FCC solutions.
MAXOFIN
Offers the ability to adjust propylene yield, propylene/ethylene ratio and olens/ liquid fuels ratio as market conditions demand
ATOMAX-2 Feed Nozzles
Produces 43 percent smaller droplet size than the leading industry ATOMAX-1 nozzles, and developed by KBR in cooperation with ExxonMobil
Riser Quench Technology
Improves gasoline yield and octane, and prevents over-cracking that result in undesirable products
Closed Cyclone Riser Termination
Minimizes dry gas make and increases gasoline yield using a simple compact cyclone system
DynaFlux Stripping Technology
Reduces entrained hydrocarbons by 80 percent compared to conventional stripper designs and may achieve six percent or less hydrogen in the coke
CycloFines Third Stage Separator
Meets particulate emissions regulations, extends downstream turbine blade life, offers higher turbine efciency and less FCC downtime
Low NOx Regeneration
Provides Low NOx emissions and uniform combustion in the regenerator bed, minimum ue gas afterburning and less catalyst deactivation
REGENMAX
Reduces regenerator emissions and entrainment and provides clean catalyst burning under partial CO combustion at minimum investment
Dense Phase Catalyst Cooling
Offers the most reliable Catalyst Cooler that provides complete exibility in the regenerator
To learn more, visit: FCC.kbr.com or e-mail rening@kbr.com.
MAXOFIN
Fluid Catalytic Cracking Technology
Keeping Pace with Rising Demand for Propylene

Maximizing Light Olens
Reneries and petrochemical plants are nding it difcult to keep pace with the increasing worldwide demand for propylene. Historically, steam crackers have satised this demand through co-product propylene but now the supply is lagging demand. As more steam crackers use ethane feedstock and produce little propylene, there is an increasing need for processes that produce large quantities of propylene with less ethylene co-product. The MAXOFINTM FCC process offered by KBR and ExxonMobil lls this niche and helps reners stay competitive by combining a high ZSM-5 content additive with KBR proven OrthoowTM FCC hardware. This combined technology maximizes propylene production from conventional FCC feedstocks while producing much less ethylene than would result from traditional steam cracking.
Enhanced Flexibility
Reners today require a technology that can respond to market demands. KBRs MAXOFIN can produce 20 wt% or more propylene from FCC feedstocks, yet still maintain the exibility to produce fuels when market demand shifts. When the margin between propylene and fuels is low, the MAXOFIN FCC can operate as a conventional FCC to produce mostly gasoline, and when the demand of propylene is relatively high, the process can maximize propylene at the expense of gasoline. If markets require distillate and propylene, our MAXOFIN FCC process allows reners to run the primary riser at low conversion to preserve the distillate yield. Light naphtha and C4s formed in the primary riser can be recycled at more severe conditions in the second riser to maximize conversion of these components to propylene. Besides processing FCC recycle streams; the high severity second riser can also accept naphthas and C4s from elsewhere in the renery complex, such as coker naphtha and C4s. Parafnic naphthas, such as light straight run, can receive an upgrade in the MAXOFIN unit to increase octane of the straight run naphtha while adding to the units propylene yield.
Reners now have an easy and exible means of adjusting propylene production, propylene/ethylene ratio and olens/fuels ratio as market conditions dictate.
To learn more, visit: FCC.kbr.com or e-mail rening@kbr.com
MAXOFIN
Produce the Molecules You Want with Minimum Byproduct

Economic Factors to Consider
While naphtha yield is limited in the high severity propylene operating mode, octane and BTX content of the MAXOFINTM FCC naphtha product is improved greatly relative to that from a conventional FCC unit. In addition to the BTX, reners can economically recover ethylene produced by the MAXOFIN FCC process for use as high value petrochemical feedstock. The process also allows reners to upgrade lower-valued naphtha streams that do not t into more lucrative product blends produced by the renery.
Boost Product Value Now

Maximizing high value propylene and other petrochemicals from FCC operations will only occur with an on-purpose technology. With KBRs MAXOFIN FCC, reners can achieve greater propylene yield while maintaining product exibility to remain competitive in changing markets.
High Value Products from MAXOFINTM FCC.
DynaFlux S tripping Technology

Greater efciency, enhanced performance

Safeguard Reactor Products
Upgrades to FCC units typically increase catalyst circulation which elevates stripper catalyst ux rates.This increase signicantly reduces stripper efciency by entraining hydrocarbon product gases into the regenerator. Once entrained, regenerator temperatures rise requiring the stripper to use additional combustion air while more hydrocarbon product is burned and lost.
Managing Flux Rates

KBR DynaFlux stripping technology addresses two challenges seen in conventional strippers: high local catalyst ux and poor lateral mixing. Developed jointly by KBR and ExxonMobil, DynaFlux technology allows the FCC stripper to effectively manage elevated ux rates. DynaFlux consists of three main components: two-stage stripping, the Flux Tubes proprietary bafe and Lateral Mixing Elements (LME) that increases the mean catalyst residence time, minimizing ow short-circuiting while improving mixing.
Top down cross section view
Reducing Hydrocarbons, Increasing Circulation

Many FCC units employ a two-stage stripper, but when coupled with our DynaFlux technology, unstripped hydrocarbons are reduced by up to 80 percent. Once a specic, critical ux rate is passed, stripper efciency plunges and ooding occurs. Flux Tubes extend the operating range of the stripper to prevent ooding and provide a signicant efciency gain without increasing stripper diameter.
With KBR DynaFlux, reners can expect lower regenerator temperature, increased catalyst circulation and higher conversion.
Save the Hydrocarbons

KBR turns visions into reality with our proven DynaFlux stripping technology. Together, we can design, install, upgrade or optimize FCC solutions.

High-efciency, robust abatement solution

Flue gas from regenerator Clean ue gas
Achieving Environmental Requirements

Now reners can meet environmental requirements with CycloFines Third Stage Separator system. KBRs CycloFines uses patented technology and a proprietary design to remove catalyst nes from FCC ue gas. The maximum allowable particulate emission at the stack dictates the level of separation required and CycloFines offers the highest efciency of its type.
FLOW
Proven Experience
Developed by ExxonMobil and KBR in an extensive joint effort that began in 1993, CycloFines offers reners improved abatement technologies to comply with environmental particulate requirements. CycloFines technology was rst commercialized for environmental protection in September 1997 at the ExxonMobil renery in Altona, Australia.
Low Cost, High Benet

Our low-cost, high-benet solution is capable of achieving less than 50 mg/Nm3 particulates in ue gas and lower stack opacity. CycloFines demonstrates ultra-high efciency during normal usage, but also an operational robustness during upsets in the FCC regenerator operation. Our improved solution essentially captures all particles larger than ve microns in diameter.
Catalyst nes
CycloFines extends downstream turbine blade life and helps achieve higher efciency with less FCC downtime. Our solution also protects ue gas expander turbines from erosion caused when catalysts in ue gas exit the regenerator.
Comply Today
KBR turns visions into reality with CycloFines Third Stage Separator. Together, we can design, install, upgrade or optimize FCC solutions.

Market-leading solution to enhanced yields

Maintain Desired Yields
Rapid removal of product vapors from FCC converters after riser cracking is paramount to maintaining desired yields. Our Closed Cyclone Riser Termination system, developed jointly by KBR and ExxonMobil, consists of interconnecting ductwork that routes product vapors directly into secondary cyclones and out of the converter. Unlike some competing systems, our proven system is the market-leading solution to preserving desired product.
Powerful Solution, Unrestricted Heat Up

Our Closed Cyclone Riser Termination system is mechanically robust and provides improved catalyst retention. Reners using our technology can expect reduced vapor residence time that signicantly minimizes post-riser thermal cracking. This system essentially eliminates dilute phase catalytic cracking and improves coke selectivity. Yield benets include less dry gas, less butadiene, less bottoms and more gasoline.
Reliable, market-leading riser termination system with lower risk of catalyst carryover.
Prevent Thermal Cracking

Closed cyclone technology is a simple solution for improving yields for revamp applications. The interconnecting ductwork to close cyclones in the FCC reactor/disengager is readily adaptable to existing cyclone systems. Reners using our closed cyclone solution can reduce counter-productive effects of thermal cracking and extract enhanced FCC yields.
Enhance Yields Now

KBR turns visions into reality with our proven Closed Cyclone Termination solution. Together, we can design, install, upgrade or optimize FCC solutions.
ATOMAX-2 Advantage
Advanced design, superior performance

ATOMAX-2 Advantage
Uniform atomization boosts yield & capacity
Achieving optimal yields from your FCC unit is heavily dependent on the feed injection system providing both rapid vaporization and intimate contact between the oil and catalyst. Feed injection improvements can reduce coke and dry gas make, resulting in higher conversion and improved selectivity toward premium products. ATOMAX-2 fan-shaped design enables small droplet output and a wide angle spray, and has shown gasoline yield improvements as high as 5 vol% and conversion increases of over 4 vol%.
Erosion resistant design improves reliability and reduces maintenance costs

Reliability and performance are essential to your operations. ATOMAX-2 unique erosion resistant design improves reliability and reduces maintenance costs. Thats why the typical run time of an ATOMAX-2 feed nozzle is at least 4 years. Whats more, the secure seal of our proprietary packing system helps avoid coke build-up and enables easy removal for inspection or maintenance. Simple, modular design makes installation of complete systems a snap.
Modest oil pressure requirements reduce utility and equipment costs

Keep your utility costs down by investing in a system that is designed for lower gas and steam injection rates at the base of the riser. Steam pressure powers most of the energy for atomization and mixing, eliminating costly pressuring of liquid feed.
ATOMAX-2 provides optimal yields and reduces energy costs
High Return on Investment

Attractive retrofit economics with payout time often six months or less. Contact KBR Technology to learn more about ATOMAX-2 feed nozzles and other solutions for optimizing FCC operations.
Low NOx Regeneration

Proprietary design, compelling results

Our proprietary, counter-current regenerator design part of the KBR alliance with ExxonMobil produces lower NOx emissions than other types of regenerators by enabling a de-NOx reaction within the regenerator itself. For any given nitrogen feed, our regenerator produces 60 to 80 percent less NOx than others. This breakthrough technology provides reners with a cost-effective solution to NOx abatement without post-treatment of FCC ue gas.
de-NOx in the Regenerator
From Grassroots to Revamps

Besides installing our technology in grassroots units, KBR has implemented counter-current technology in revamps of side-entry regenerators originally designed by other licensors. Performance in these revamps has achieved as much as 80 percent reduction in NOx.
Positive Reactions
In our regenerator, spent catalyst is evenly distributed across the top of the regenerator bed, causing a chemical reaction: 2 C + 2NO 2 CO + N2. Only 5 to 7 percent of the nitrogen in the coke escapes as NOx. The remainder converts to harmless N2 by the reaction with spent catalyst at the top of the regenerator bed. Only KBRs patented spent catalyst distributor can deliver these results. Benets of this sytem include: Reduction of NOx emissions by 60 to 80 percent Proven, proprietary design Optimal catalyst bed density distribution Elimination of need for post treatment of FCC flue gas
KBRs counter-current regeneration design enables a de-NOx reaction within the regenerator itself.
Ready for Results?

KBR turns visions into reality with Low NOx Regeneration.Together, we can design, install, upgrade or optimize FCC solutions.
Dense Phase Catalyst Cooler
Increase the Flexibility of FCC Operations

Water
Water / Steam Catalyst
Reners have an appetite for processing heavy FCC feedstocks and a desire to produce more propylene. These operations result in high regenerator temperatures and lead to: Accelerated catalyst deactivation Need for exotic mechanical design to avoid equipment damage Degradation of cracking selectivity The KBR dense phase catalyst cooler provides reners with a exible and robust solution to maintain the desired regenerator temperature when processing heavy feedstocks and performing high severity operations.
Design Features
Key Features of the KBR Dense Phase Catalyst Cooler: The cooler design operates with steam and water in the tubes and hot catalyst owing at low velocity in the shell The tubes are double bayonet design with boiler feed water owing downward in the inner tube, and steam and water owing upward through the annulus The cooler is instrumented so that the catalyst ow rate through the cooler adjusts automatically to changes in feed and reaction conditions as needed to maintain the desired regenerator temperature
Fluidization Air
Catalyst KBR FCC Dense phase catalyst cooler meets the challenges of process exibility and mechanical reliability
Dense Phase Catalyst Cooler

Why a KBR Dense Phase Cooler?

Enhanced Flexibility
Operating exibility is one of the distinguishing features of the KBR Catalyst Cooler. A gas vent line at the top of the cooler shell prevents catalyst back-mixing between the cooler and regenerator whenever the cooler catalyst circulation is stopped. This provides complete heat removal turndown capability.
Proven Reliability
The tubes are free hanging from a single tube sheet at the top of the exchanger, which has several important ramications with respect to cooler reliability. Downward hanging tubes allow the cooler shell uidization air to be introduced well Regen Temperature Control 725 below the tubes. This prevents the possibility of cooler uidization air jet impingement on the tubes which could cause an erosion related 720 tube failure The steam is generated in up-ow between the 715 inner and outer tubes. This enables the cooler to utilize natural boiler feed water circulation, eliminating the need for forced boiler feed wa710 ter circulation pumps along with their associated cost and reliability issues 705 The orientation of the tube bundle also facili0 5 10 15 20 Time (Hours) tates maintenance and inspection of the cooler because the bundle can be pulled from the top Cat cooler adjusts automatically to feed changes. of the shell
Regen Temp (C)
200
150 Cooler duty % of Design
100
50
0 25
Take control of the FCC Heat Balance

The challenges of feed stock exibility and reliability are met with the KBR FCC dense phase catalyst cooler. The cooler will allow FCC units to process feedstock ranging from clean vacuum gas to residues containing 7% CCR or more while also allowing operations at ultra-high reactor temperatures. Furthermore, the avoidance of erosive conditions in the design of the cooler will prevent the cooler from limiting FCC run lengths. At this time, there are 16 commercial KBR dense phase catalyst coolers in operation with a total design duty of more than 1.3 Billion BTU / Hr.
Residue FCC Technologies
Residue FCC Performance and Value

Residue FCC (RFCC) converts low value residual feeds and deasphalted oils from heavy crudes to high value light olefins, gasoline and distillates. KBRs FCC Technology solution offers unmatched processing flexibility along with simplicity of design and operation.
FCC Technologies and Advanced Features

Orthoflow FCC Converter Compact, low pressure design operates in partial or full CO combustion Advanced Reaction Hardware and low pressure operation combine to provide superior yield performance Catalyst Cooler Proven reliability and complete operating flexibility in FCC regenerator heater removal Counter Current Catalyst Regeneration Single-stage regeneration lowers investment cost and improves energy efficiency CycloFines Third Stage Separator Meets particulate emissions regulations, offers higher turbine protection for increased efficiency and less FCC downtime
Successful FCC Projects and Experience

Experienced KBR Technology Team ensuring on-time project execution and commissioning assistance Over 70 years of KBR FCC experience backed by results and reputation to meet or exceed performance expectations Over 122 grassroot units designed History of significant FCC firsts by KBR A commitment to improving current technologies and commercializing new technologies Petrochemical and refining product recovery expertise FCC unit in Altona, Australia
Unique Features of KBRs Residue FCC Technology

Low long-term cost of ownership assured through inherent capital and production cost advantages of KBR FCC technology
Orthoflow FCC Process flexibility and reliability derived from the elegance of simplicity
Our Orthoflow FCC combines the disengager, stripper, and regenerator vessels into a single, self- supporting vessel. This arrangement produces several operational and cost advantages: Low overall converter height Minimum structural steel and plot area requirements Short regenerated and spent catalyst standpipes allowing robust catalyst circulation Uniform distribution of spent catalyst in the stripper and regenerator especially needed in large FCC units Compatible with future addition of second riser for maximum propylene and ethylene production (MAXOFIN) Ability to operate in partial burn or complete combustion Single regenerator flue gas system lowers investment costs and maximizes turboexpander utilization Flexible unit can process Resid or VGO at optimum conditions - two stage regeneration is not required Our unique design minimizes the cost of construction and also reduces the amount of eld mechanical work and required plot space.
Riser Quench Technology

Higher gasoline yields are achievable through KBRs Riser Quench technology by: Increased mix zone temperature resulting in improved vaporization of the feed critical when processing resid feedstocks Increased catalyst circulation to the riser at constant riser outlet temperature Our riser quench technology improves yields and prevents over-cracking, which results in undesirable products
Catalyst Cooler
The most reliable Catalyst Cooler meets the flexibility requirements of changing feedstock and processing objectives in resid cracking. The Catalyst Cooler provides flexibility to: Process heavier feedstocks Lower regenerator temperature minimizes dry gas yield and catalyst deactivation Allow high reactor temperature operations for maximum propylene Optimize conversion by controlling catalyst-to-oil ratio
To learn more, visit: FCC.kbr.com or e-mail refining@kbr.com
Environmental Performance and Safety

Counter-Current Catalyst Regeneration
Our counter-current regeneration with multipoint spent catalyst distributor offers the following environmental benefits: Minimizes catalyst deactivation for less spent catalyst disposal Minimizes NOx emissions when operated in full CO combustion Minimizes CO emissions and afterburn associated with poor catalyst distribution
Spent Cat Air

Our TSS solution is capable of achieving less than 50 mg/Nm3 particulates in flue gas and lower stack opacity to comply with environmental particulate requirements. The TSS essentially captures all particles larger than five microns in diameter, extending downstream turbine blade life and helping to achieve higher efficiency with less FCC downtime. Counter - Current Regenerator
Operator Training Simulator

Advanced technology allows KBRs operators to simulate all aspects of plant operations and controls, as well as startups, shutdowns and emergencies. The major driving factors for the adoption of an OTS system: Improved profitability Enhanced plant operations Extended equipment life
Flue gas from regenerator

FLOW
Clean ue gas
Catalyst nes
Cyclones Third Stage Seperator
Residue FCC Technologies
Commitment to Technology Improvement

Over 70 Years of Experience
Put generations of leadership and know-how to work for your operations. KBR participated in the worlds first commercial FCC unit located in Louisiana in 1942. Since then, we have licensed more than 125 FCC units worldwide. This expertise, along with decades of operational insight, ensure that KBR FCC units are well designed, reliable and easy to operate.
Legacy of Innovation
Flux Tube Stripper Baffles Improve stripping efficiency Reduce unstripped hydrocarbon Most efficient TSS available Market leading nozzles Smallest droplets Best coverage of riser Produces high yields of propylene Flexibility for max gasoline or max olefins Better utilization of stripper cross section Reduce delta coke Provides staged regeneration in a simple, single regenerator vessel Present Day Orthoow FCC
CycloFines Third Stage Separator ATOMAX-2 Feed Injection Nozzles
MAXOFIN FCC
Lateral Mixing Elements
RegenMax
1942 FCC Design
FCC Revamp
We Did It First and Never Stopped Improving

Providing refiners the best path to a more profitable operation is the goal of KBRs FCC Fluid Catalytic Cracking Revamp Program, KBR has nearly 70 years of FCC design, engineering, procurement and construction services experience which gives us the insight to map the right solution for our clients. KBR pioneered the initial development of FCC technology in the late 1930s, built the first commercial FCC unit for Exxon in 1942, went on to design more than 100 others worldwide and since 2000 has completed major revamps at more than 50 units worldwide as well as more than 30 feed ATOMAX nozzle upgrade projects. Keeping our focus on efficiencies, constantly pursuing new process improvements and fine-tuning our approach to FCC operations gives us a unique and unrivaled ability to customize a revamp that will offer a maximum return on investment. We deliver fast-tracked implementation and turnarounds on units that employ other licensor technologies as well as our own.
Typical Goals of an FCC Revamp Include:

ATOMAX-2 Feed Nozzles
Increased capacity and conversion Greater feedstock flexibility Improved gasoline yield and octane Optimized light olefins yields Integrated refinery operations
Enhanced reliability, maintainability, environmental compliance and on-stream time
Regenerator Air Distributor Upgrade
Increased Capacity, Better Yield and More Valuable Products

ATOMAX-2 TM feed nozzles produce a 43% smaller droplet size than the previous generation and industry leading ATOMAX-1 nozzles. More abundant, smaller droplets provide better faster feedstock vaporization for improved product selectivity. Better coverage of the riser cross section is achieved by maintaining a flat fan-shaped spray pattern. Uniform atomization with a lower feedstock pressure drop results in increased energy savings and equipment design economies. DynaFluxTM stripping technology, featuring proprietary Flux Tubes TM and Lateral Mixing Elements TM, reduces entrained hydrocarbons by approximately 80% compared to conventional stripper designs and may achieve 6% or less hydrogen in the coke. The benefits are lower regenerator temperature, increased catalyst circulation and higher conversion. Higher feed mix zone temperatures increase vaporization of heavy feedstock, and improve gasoline yield and octane. KBR Riser Quench technology allows for a 25 to 50 degree F increase in mix zone temperature by introducing quench oil downstream of the feed mix zone on the riser. In addition, the rapid quench prevents secondary reactions and over-cracking that result in undesirable products.
Flue Gas System Reconguration
Closed Cyclone technology reduces vapor residence time and catalyst concentration in the disengager dilute phase to minimize both post-riser thermal and catalytic cracking. Yield benefits include less dry gas, less coke, less butadiene, less bottoms, and more gasoline. The Closed Cyclone Riser Termination system is also mechanically robust and provides excellent catalyst retention with the application of two stages of cyclonic separation.
Improved Reliability, Streamlined Operability and Environmental Compliance

Orthoflow FCC makes full use of cold wall carbon steel construction with modern monolithic refractory which provides longer service life at a lower cost because insulating refractory keeps the steel shell in the optimum temperature range for maximum strength and avoidance of thermal degradation. The inherent integrity of cold wall construction results in longer run lengths and less maintenance during turnarounds and shutdowns.
Third Stage Separator Upgrade using CycloFines Technology
FCC Revamp
CycloFines Third Stage Separator technology removes particulate emissions from the regenerator flue gas and enables less than 50 mg/Nm3 particulates and lower flue gas opacity. KBR also offers counter-current spent catalyst regeneration technology for low NOx emissions and minimized afterburning utilizing a patented self aerated spent catalyst distributor and a robust pipe air grid distributor.
Higher Productivity and Prot with KBRs FCC Revamp Program

Refiners around the world have benefited from KBRs customized revamps that blend advanced FCC process technology and reliability improvements to achieve a competitive advantage in todays rapidly changing business environment.
For more information about FCC Revamps and Expansions e-mail us at refining@kbr.com
www.kbr.com 2007 Kellogg Brown and Root LLC All Rights Reserved Printed in U.S.A.
070114 08/07 K08077
www.kbr.com/technology

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Fluid Catalytic Cracking

Unsurpassed innovation, performance and reliability

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