Fluid Catalytic Cracking

KPE resources include highly experienced Fluid Catalytic Cracking 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 applies to the FCC reactor and regenerator sections as well as the product recovery and flue gas systems.

Refining: Fluid Catalytic Cracking (FCC) Unit Design

The know-how of our experts evolves through the 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.

Optimal Design and Fabrication

Success for our customers comes when the 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.

Fluidized Catalytic Cracking Projects

While the Fluid Catalytic Cracking 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 the identification of cost-effective unit modifications and then execution of associated projects. Some examples follow. Learn more about the markets we serve and the process studies, project development, and execution methods at KPE. If you have any comments, questions, or concerns be sure to contact our team of experts today.

Areas We Serve:

Texas

Utah

Louisiana

Oklahoma

New Mexico

Kansas

Washington

Oregon

California

Activities:

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)

Results:

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