Fluid Catalytic Cracking

As the heart of a refinery, the Fluid Catalytic Cracking (FCC) unit is continuously pushed to the limit. Refiners are continually evaluating potential FCC modifications to increase capacity and improve product yields, as well as to maximize on-stream factor and mechanical reliability in order to be more profitable while simultaneously meeting stringent environmental regulations.

KBR is well positioned to accomplish these tasks. We are constantly pursuing new process improvements and fine-tuning our approach to catalytic cracking operations, based on real world experience and on an institution of technology development.

Commercial Applications

With over 120 grassroots FCC units licensed to date, and broad application to units originally licensed by others, KBR is an industry leader in FCC. This leadership extends beyond process technology into related areas of mechanical design, engineering, procurement, construction and technical service, around the world. KBR offers three process technologies, all based on KBR's proprietary OrthoFlow™ FCC Converter that fit best with the refiners processing objectives, irrespective of the feedstock or product yield slate.

  • FCC is used for the conversion of gas oils and residues to light olefins, high octane gasoline and distillates using the compact, self supporting Orthoflow converter.
  • Resid FCC (RFCC) converts low value residual feeds and deasphalted oils from heavy crudes to high valued light olefins, gasoline and distillates.
  • MAXOFIN™ FCC offers refiners greater returns by maximizing propylene yields from FCC feedstocks. Over 20 per cent weight propylene yield can be produced from gas oils by combining the effects of enhanced ZSM-5 catalysts and proprietary hardware.

Values and Benefits

As the FCC unit is continuously pushed to the limit, refiners are continually evaluating potential FCC modifications to:

  • Increase capacity
  • Improve product yields
  • Maximize yields of specific products
  • Maximize on-stream factor and mechanical reliability

The results are usually indicated by higher profit margins while simultaneously meeting stringent environmental regulations.

Technology Information

KBR has nearly 70 years of FCC design, engineering, procurement and construction services experience. KBR pioneered the initial development of FCC Technology in the late 1930’s with the world's first commercial FCC unit at a Baton Rouge, Louisiana refinery. KBR has since designed more than 100 FCC units worldwide and since 2000 has completed major revamps at more than 50 units with over 30 ATOMAX™ feed nozzle upgrades.

Process Technologies

KBR offers three versions of its FCC process technology platform, all based on KBR's proprietary OrthoFlow™ FCC Converter. To optimize the operation of the plant and provide hands-on training for FCC operating personnel, KBR offers the following value added computer software:

  • Orthoflow™ FCC - Traditional FCC Process
  • MAXOFIN™ FCC - Maximum Propylene FCC Process
  • Resid FCC (RFCC) - FCC Process Designed for Processing of Residual Oils
  • FCC Advanced Process Control (APC)
  • FCC Operating Training Simulator (OTS)

Mechanical Equipment Technologies

KBR FCC technology and know-how are provided in the form of proven FCC mechanical equipment technologies that give refiners FCC process performance and operational flexibility along with the reliability needed to sustain the profitability of the FCC operation. KBR's FCC mechanical equipment technologies include:

  • ATOMAX-2™
  • Riser Quench Technology
  • Closed Cyclone Riser Termination
  • DYNAFLUX™ Stripping
  • Low NOx Regeneration
  • CycloFines™ TSS
  • Dense Phase Catalyst Cooler

FCC Technical Support

Following start up of the unit as well as during normal operation, technical service engineers continue to assist the refiner in gaining maximum value from their investment in KBR technology through routine refinery visits and consultation.

This includes services such as:

  • Process optimization
  • Operating
  • Troubleshooting assistance
  • Unit inspections
  • Pilot plant evaluations of feedstocks and catalysts.

For more information on KBR FCC Technology please visit our KBR FCC publications or contact a KBR Technology representative by completing the contact form.