Fluid Catalytic Cracking (FCC) Applications

• Catalyst and Gas Oil Feed: The process employs a fluidized catalyst, most commonly a zeolite-based material, to crack hydrocarbons.
• Vaporization and Cracking:
  • Gas oil feed is vaporized in the riser reactor upon contact with the fluidized catalyst under specific conditions of heat and pressure (above 750°F).
  • Hydrocarbons (HC) are thermally and catalytically cracked on the surface of the catalyst into smaller molecules.
• Spent Catalyst Disengagement: Once the reaction is complete, the spent catalyst is disengaged from hydrocarbon vapors via cyclones or separators.
• Cracked Vapor Processing:
  • The cracked hydrocarbon vapors are collected, condensed, and fractionated into various product streams, such as LPG, gasoline, light cycle oil, and slurry oil.
• Catalyst Regeneration: The spent catalyst, coated with coke from the cracking reaction, is transported to a separate regeneration vessel, where the coke is burned off using controlled air supply.
• Recycling of Catalyst: The regenerated catalyst is returned to the riser reactor to repeat the cycle, ensuring continuous operation of the FCC unit.

Cracked Gas Compressor Protection – L/G coalescer
Fuel Gas Amine Contactor – L/G coalescer
LPG Amine/Caustic Contactor – filter and L/L coalescer - C3 olefins will be treated by amine (H2S) and caustic, C4 by caustic (remove mercaptans)
Water in Distillate (LCO) – Filter and L/L coalescer – water from steam stripping in fractionators (sent to H/T)
Catalyst Fines Removal from Flue Gas – Automated blowback filtration
Catalyst Fines Removal from Slurry Oil – Automated backwash filtration