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Computational modeling plays an increasingly important role in understanding gas-particle flow dynamics in the Fluid Catalytic Cracking process. TechnipFMC actively uses tools such as computational fluid dynamics (CFD) for FCC design validation and as a troubleshooting tool. CFD provides both the qualitative and quantitative information needed to study, and understand, how hardware modifications and operational changes will impact gas-particle flow behavior and hence the overall performance of the unit.

This paper provides two revamp case studies, one of an FCC regenerator and the other an FCC riser. The FCC regenerator revamp incorporates improvements to the spent catalyst distributor and regenerator catalyst standpipe to mitigate operational problems and improve mechanical reliability. The FCC riser revamp includes design modifications to incorporate larger diameter and longer riser to achieve target residence time at increased capacity. This paper describes how CFD modeling tools were used to confirm the adequacy of the proposed hardware changes, fine tune the design and evaluate the performance to minimize the potential risks on startup. The paper also highlights key pre and post turnaround performance results.