UOP FCC Innovations Developed Using Sophisticated Engineering Tools

Fluid Catalytic Cracking (FCC) technology has been a part of the petroleum industry since the 1940s. Yet, despite being a very mature technology, as many refiners move their FCC operations from fuels production to higher value products, continued development is vital to help reinvent the role of the FCC unit. Through the commercialization of world record scale FCC units, technical discoveries are emerging, which are providing opportunities for improvements across units of all size. As FCC technology is pushed into new areas of production, more is learned about controlling hydrocarbon species versus just a boiling range of fuels products.

Advanced diagnostics, design tools and pilot plant operations are accelerating process development and have resulted in several technical innovations. Through the combination of sophisticated engineering tools, Computational Fluid Dynamic (CFD) modeling, and radioactive tracer and tomography combined with physical inspection reports and commercial yields, technology advancements are being brought to market more quickly and with greater success.

This paper will highlight advancements in regenerator capacity, emissions reduction and riser feed distribution. It will demonstrate how innovative tools are being used to both improve existing FCC designs and move an aged technology towards true growth opportunities.