Dense Phase Catalyst Cooler

Dense Phase Catalyst Cooler Enlarge Photo

Dense Phase Catalyst Cooler: Improve circulation, eliminate back mixing and erosion

A variable duty catalyst cooler is the key to meeting the flexibility requirements of changing feedstock and processing objectives. As feedstocks become heavier (high Conradson Carbon values), additional coke forms in the reaction process and adheres to the catalyst. Coke is burnt off the catalyst in the regenerator releasing heat in the process. To maintain reasonable FCC regenerator temperatures when coke yields increase, one option is the installation of external catalyst cooling. The strengths of KBR Dense Phase Catalyst Cooler include:

  • Upflow boiling/natural circulation vs. downflow boiling/forced circulation - operating data has shown that natural circulation of boiler feed water is more reliable, since the tube bundle is always flooded with water and there is no need for a circulating pump.
  • Vent line - eliminates back mixing during periods when catalyst flow through the cooler is stopped, and to ensure a smooth non-turbulent entry of catalyst from the FCC regenerator and providing turndown to essentially zero duty.
  • Elimination of erosion - most important element for long term reliability. Our design locates the fluidization air distributor a maximum distance away from the tubes making tube erosion from air jet impingement impossible.
  • Bundle removal - cooler placement allows for the tube bundle to be easily removed from the top for inspection and maintenance. This concept can minimize unit turnaround.
  • Commercial experience - At this time, there are sixteen commercial KBR dense phase catalyst coolers in operation with a total design duty of more than 1.3 Billion BTU / Hr.

For more information on KBR’s Dense Phase Catalyst Cooler, please view the Dense Phase Catalyst Cooler Brochure.