Fluid Catalytic Cracking

KPE resources include highly experienced FCC process and mechanical professionals to assist our customers with the identification and correction of impediments to efficient and reliable FCC unit operations. The available expertise at KPE apply to the FCC reactor and regenerator sections as well as the product recovery and flue gas systems.

The know-how evolves through continual pursuit of improvements in design methods, materials and equipment supply. KPE maintains relationships with key manufacturers of the related FCC equipment components including refractory lined reactor and regenerator vessels, cyclones, fractionators and trays, large refractory lined transfer lines, catalyst valves, expansion joints and internal components.

Success for our customers comes when process, mechanical design and fabrication considerations are synchronized for the benefit of FCC unit construction, operation and maintenance. Metal and refractory provide the platform, while heat and catalyst drive the process. At KPE, it’s a team effort.

While the FCC process is very flexible, changes in feed quality or desired product yield provide opportunities for optimizing the operation and design of the equipment. KPE stands ready to assist customers with optimizing the operation as well as with identification of cost effective unit modifications and then execution of associated projects. Some examples follow.


  • Field troubleshooting and optimization
  • Inspection of FCC unit internals
  • Assembly of accurate process base case data for simulation of existing equipment
  • HYSYS and PRO-II Modeling of main fractionator and gas concentration units
  • Conceptualization of needed solutions
  • Thermal / mechanical stress analysis including finite element analysis (FEA)
  • Layout of new facilities considering operability, construction and maintainability
  • Preparation of Study Reports, Basic Engineering Packages and FEL deliverables
  • Estimation of costs and benefits for process unit additions and revamps
  • Solicitation and evaluation of solutions from equipment vendors and process licensors
  • Detailed design, procurement and construction (EPC)


  • Increased valuable product production with improved reactor technology
  • Improved regeneration and lower emissions with improved spent catalyst and air distribution
  • Improved fractionation and energy efficiency with rebalancing of main fractionator heat loads
  • Processing heavier feedstock with a catalyst cooler or partial CO combustion
  • Meeting air quality standards with flue gas emission controls
  • Processing lighter FCC Feeds with debottlenecking of gas concentration units
  • Utilization of spare FCC capacity
  • Integration of refinery and petrochemical plants
  • Recovering polymer grade propylene
  • Improved mechanical integrity
  • Resolved constructability issues