Fluid Catalytic Cracking

Unsurpassed innovation, performance and reliability

Since 1990, KBR has designed more than a dozen FCC units and revamped more than 160 FCC units worldwide
Meeting Todays Challenges
Refiners today face the choice of purchasing light sweet crudes at a premium price or investing in bottom-of-the-barrel upgrading. Yet with stringent environmental requirements and a dwindling supply of quality crudes, upgrading is the logical solution to remain competitive.

Frontrunner in FCC
Not only are we a recognized leader in FCC, but we also pioneered the technology in the late 1930s. This led to a KBR and ExxonMobil joint venture alliance in the design, construction and operation of the worlds first commercial FCC unit at ExxonMobils Baton Rouge, Louisiana refinery in 1942. It also marked the beginning of a solid partnership with ExxonMobil in FCC technology that remains today.

Refinery ROI
Our FCC experts hold industry-leading experience in designing, engineering, procurement and construction services. We evaluate modifications to increase capacity, improve and maximize product yield and enhance on-stream factor and mechanical reliability.

At the ExxonMobil FCC project in Altona, Australia, KBR proved that FCC solutions offer long term reliability and low capital costs.

Our experts can help clients:

Accelerate ROI, ROCE, RONA and cash flow Design, engineer, construct and service FCC units Increase profitability Achieve cost objectives Reduce safety incidents Overcome resource constraints Identify new opportunities for improvement Revamp and replace technology Extend the life of FCC investment Sustain benefits Stay current with environmental regulations

Fluid Catalytic Cracking

KBRs Technology Center (KBRTC) contains numerous pilot plants, analytical laboratories and pilot plant fabrication facilities and a talented staff of engineers, chemists, specialists and craftsmen who develop and commercialize new and improved process technologies.

Long-Term Reliability
Rigorous testing, ongoing research, catalyst evaluation, feedstock characteristics and product yield assessment make KBR a cut above. With KBR, our clients count on unmatched FCC solutions that are low in capital cost and high on quality, long-term reliability and operability.

Rigorous testing, ongoing research, catalyst evaluation, feedstock characteristics and product yield assessment make KBR a cut above.

Technical Services
Following start up of the unit as well as during normal operation, technical service engineers assist refiners in gaining maximum value from investment in KBR technology through routine refinery visits and consultation. We maximize clients ROI using our licensed technologies through technical services for operations and turnarounds.

Lower Capital Costs

Our joint engineering teams developed the KBR Orthoflow FCC process technology, which includes the compact, self-supporting Orthoflow converter and combines the disengager, stripper and regenerator vessels into a single vessel. This unique design minimizes the cost of construction, and also reduces the amount of field mechanical work and required plot space.

Fluid Catalytic Cracking

KBR provides testing, training and process controls to help meet refinery objectives
FCC Advanced Process Controls
KBRs Advanced Process Control (APC) is especially beneficial for FCC units due to their complexities and large number of interactive variables. Our APC system consists of: Severity Control Combustion Control Pressure Balancing and Control Fractionator Control Vapor Recovery Unit (VRU) Control

APC gets you closer to targets and constraints, improves stability and makes operation seamless. This translates to enhanced operational information and faster responses to changes in refinery objectives.

Operator Training Simulator

Successful start-up of grassroots FCC units is dependent on a well-trained operations team. To ensure your team is ready for anything, KBRs operator training simulator provides a realistic dynamic simulation of the FCC process configured to resemble the actual FCC operator interface.
KBRTC specializes in cold flow modeling the simulation of process characteristics at near ambient temperatures and pressures. Creating realistic cold flow models is a unique talent and KBR is a leading practitioner of this technique.

Advanced technology allows KBRs operators to simulate all aspects of plant operations and controls, as well as startups, shutdowns and emergencies.

Leading-edge technology and service that spans 100 years

Fluid Catalytic Cracking

Quick, Safe & Effective Revamps

KBRs approach to revamping draws upon unrivaled skill in all aspects of FCC technology. For fast-track implementation of the latest technology improvements, KBR and our industrial fabrication and construction partner, InServ, provide lump-sum turnkey revamp and turnaround solutions that include: Increased capacity and conversion Greater feedstock flexibility Gasoline yield improvement Octane improvement Light olefins yield optimization Closer integration with other refinery operations Improvements in reliability, maintainability, environmental compliance and on-stream time

Fluid Catalytic Cracking

Design solutions. Optimize processes. Enhance productivity. Accelerate ROI.

Why Wait?
KBR turns visions into reality with our proven FCC technologies and advanced features from our alliance partner ExxonMobil. Together, we can design, construct and optimize FCC solutions.

MAXOFIN

Offers the ability to adjust propylene yield, propylene/ethylene ratio and olefins/ liquid fuels ratio as market conditions demand

ATOMAX-2 Feed Nozzles

Produces 43 percent smaller droplet size than the leading industry ATOMAX-1 nozzles, and developed by KBR in cooperation with ExxonMobil

Riser Quench Technology

Improves gasoline yield and octane, and prevents over-cracking that result in undesirable products

Closed Cyclone Riser Termination

Minimizes dry gas make and increases gasoline yield using a simple compact cyclone system

DynaFlux Stripping Technology

Reduces entrained hydrocarbons by 80 percent compared to conventional stripper designs and may achieve six percent or less hydrogen in the coke

CycloFines Third Stage Separator

Meets particulate emissions regulations, extends downstream turbine blade life, offers higher turbine efficiency and less FCC downtime

Low NOx Regeneration

Provides Low NOx emissions and uniform combustion in the regenerator bed, minimum flue gas afterburning and less catalyst deactivation

REGENMAX

Reduces regenerator emissions and entrainment and provides clean catalyst burning under partial CO combustion at minimum investment

Dense Phase Catalyst Cooling

Offers the most reliable Catalyst Cooler that provides complete flexibility in the regenerator

To learn more, visit: FCC.kbr.com or e-mail refining@kbr.com.

MAXOFIN
Fluid Catalytic Cracking Technology

Keeping Pace with Rising Demand for Propylene

Maximizing Light Olefins
Refineries and petrochemical plants are finding it difficult to keep pace with the increasing worldwide demand for propylene. Historically, steam crackers have satisfied this demand through co-product propylene but now the supply is lagging demand. As more steam crackers use ethane feedstock and produce little propylene, there is an increasing need for processes that produce large quantities of propylene with less ethylene co-product. The MAXOFINTM FCC process offered by KBR and ExxonMobil fills this niche and helps refiners stay competitive by combining a high ZSM-5 content additive with KBR proven OrthoflowTM FCC hardware. This combined technology maximizes propylene production from conventional FCC feedstocks while producing much less ethylene than would result from traditional steam cracking.

Enhanced Flexibility
Refiners today require a technology that can respond to market demands. KBRs MAXOFIN can produce 20 wt% or more propylene from FCC feedstocks, yet still maintain the flexibility to produce fuels when market demand shifts. When the margin between propylene and fuels is low, the MAXOFIN FCC can operate as a conventional FCC to produce mostly gasoline, and when the demand of propylene is relatively high, the process can maximize propylene at the expense of gasoline. If markets require distillate and propylene, our MAXOFIN FCC process allows refiners to run the primary riser at low conversion to preserve the distillate yield. Light naphtha and C4s formed in the primary riser can be recycled at more severe conditions in the second riser to maximize conversion of these components to propylene. Besides processing FCC recycle streams; the high severity second riser can also accept naphthas and C4s from elsewhere in the refinery complex, such as coker naphtha and C4s. Paraffinic naphthas, such as light straight run, can receive an upgrade in the MAXOFIN unit to increase octane of the straight run naphtha while adding to the units propylene yield.

Refiners now have an easy and flexible means of adjusting propylene production, propylene/ethylene ratio and olefins/fuels ratio as market conditions dictate.

To learn more, visit: FCC.kbr.com or e-mail refining@kbr.com

MAXOFIN
Fluid Catalytic Cracking Technology

Produce the Molecules You Want with Minimum Byproduct

Economic Factors to Consider
While naphtha yield is limited in the high severity propylene operating mode, octane and BTX content of the MAXOFINTM FCC naphtha product is improved greatly relative to that from a conventional FCC unit. In addition to the BTX, refiners can economically recover ethylene produced by the MAXOFIN FCC process for use as high value petrochemical feedstock. The process also allows refiners to upgrade lower-valued naphtha streams that do not fit into more lucrative product blends produced by the refinery.

Boost Product Value Now

Maximizing high value propylene and other petrochemicals from FCC operations will only occur with an on-purpose technology. With KBRs MAXOFIN FCC, refiners can achieve greater propylene yield while maintaining product flexibility to remain competitive in changing markets.

High Value Products from MAXOFINTM FCC.

To learn more, visit: FCC.kbr.com or e-mail refining@kbr.com

DynaFlux S tripping Technology

Fluid Catalytic Cracking Technology

Greater efficiency, enhanced performance

Safeguard Reactor Products
Upgrades to FCC units typically increase catalyst circulation which elevates stripper catalyst flux rates.This increase significantly reduces stripper efficiency by entraining hydrocarbon product gases into the regenerator. Once entrained, regenerator temperatures rise requiring the stripper to use additional combustion air while more hydrocarbon product is burned and lost.

Managing Flux Rates

KBR DynaFlux stripping technology addresses two challenges seen in conventional strippers: high local catalyst flux and poor lateral mixing. Developed jointly by KBR and ExxonMobil, DynaFlux technology allows the FCC stripper to effectively manage elevated flux rates. DynaFlux consists of three main components: two-stage stripping, the Flux Tubes proprietary baffle and Lateral Mixing Elements (LME) that increases the mean catalyst residence time, minimizing flow short-circuiting while improving mixing.

Top down cross section view

Reducing Hydrocarbons, Increasing Circulation

Many FCC units employ a two-stage stripper, but when coupled with our DynaFlux technology, unstripped hydrocarbons are reduced by up to 80 percent. Once a specific, critical flux rate is passed, stripper efficiency plunges and flooding occurs. Flux Tubes extend the operating range of the stripper to prevent flooding and provide a significant efficiency gain without increasing stripper diameter.

With KBR DynaFlux, refiners can expect lower regenerator temperature, increased catalyst circulation and higher conversion.

Save the Hydrocarbons

KBR turns visions into reality with our proven DynaFlux stripping technology. Together, we can design, install, upgrade or optimize FCC solutions.

To learn more, visit: FCC.kbr.com or e-mail refining@kbr.com.

CycloFines Third Stage Separator

Fluid Catalytic Cracking Technology

High-efficiency, robust abatement solution

Flue gas from regenerator Clean flue gas

Achieving Environmental Requirements

Now refiners can meet environmental requirements with CycloFines Third Stage Separator system. KBRs CycloFines uses patented technology and a proprietary design to remove catalyst fines from FCC flue gas. The maximum allowable particulate emission at the stack dictates the level of separation required and CycloFines offers the highest efficiency of its type.

FLOW

Proven Experience
Developed by ExxonMobil and KBR in an extensive joint effort that began in 1993, CycloFines offers refiners improved abatement technologies to comply with environmental particulate requirements. CycloFines technology was first commercialized for environmental protection in September 1997 at the ExxonMobil refinery in Altona, Australia.

Low Cost, High Benefit

Our low-cost, high-benefit solution is capable of achieving less than 50 mg/Nm3 particulates in flue gas and lower stack opacity. CycloFines demonstrates ultra-high efficiency during normal usage, but also an operational robustness during upsets in the FCC regenerator operation. Our improved solution essentially captures all particles larger than five microns in diameter.

Catalyst fines

CycloFines extends downstream turbine blade life and helps achieve higher efficiency with less FCC downtime. Our solution also protects flue gas expander turbines from erosion caused when catalysts in flue gas exit the regenerator.

Comply Today
KBR turns visions into reality with CycloFines Third Stage Separator. Together, we can design, install, upgrade or optimize FCC solutions.

To learn more, visit: FCC.kbr.com or e-mail refining@kbr.com.

Closed Cyclone Riser Termination

Fluid Catalytic Cracking Technology

Market-leading solution to enhanced yields

Maintain Desired Yields
Rapid removal of product vapors from FCC converters after riser cracking is paramount to maintaining desired yields. Our Closed Cyclone Riser Termination system, developed jointly by KBR and ExxonMobil, consists of interconnecting ductwork that routes product vapors directly into secondary cyclones and out of the converter. Unlike some competing systems, our proven system is the market-leading solution to preserving desired product.

Powerful Solution, Unrestricted Heat Up

Our Closed Cyclone Riser Termination system is mechanically robust and provides improved catalyst retention. Refiners using our technology can expect reduced vapor residence time that significantly minimizes post-riser thermal cracking. This system essentially eliminates dilute phase catalytic cracking and improves coke selectivity. Yield benefits include less dry gas, less butadiene, less bottoms and more gasoline.
Reliable, market-leading riser termination system with lower risk of catalyst carryover.

Prevent Thermal Cracking

Closed cyclone technology is a simple solution for improving yields for revamp applications. The interconnecting ductwork to close cyclones in the FCC reactor/disengager is readily adaptable to existing cyclone systems. Refiners using our closed cyclone solution can reduce counter-productive effects of thermal cracking and extract enhanced FCC yields.

Enhance Yields Now

KBR turns visions into reality with our proven Closed Cyclone Termination solution. Together, we can design, install, upgrade or optimize FCC solutions.

To learn more, visit: FCC.kbr.com or e-mail refining@kbr.com.

ATOMAX-2 Feed Nozzles

Fluid Catalytic Cracking Technology

Advanced design, superior performance

Maximum Coverage = Outstanding Yields
Achieving optimal yields from your FCC unit is heavily dependent on the feed injection system providing both rapid vaporization and intimate contact between the oil and catalyst. This optimization is where KBR excels. Our ATOMAX-2 feed nozzles, developed by KBR in cooperation with ExxonMobil, produce an approximately 43 percent smaller droplet size than the industry-leading ATOMAX-1 nozzles.

Accelerating Value While Reducing Energy Costs

Our ATOMAX-2 feed nozzles provide at least five times more droplets in any given volume, and better coverage of the riser cross section by maintaining a flat, fan-shaped spray pattern. Using ATOMAX-2, refiners can expect a more uniform atomization across the spray. Refiners receive an added benefit of a 10 to 15 percent lower pressure drop than ATOMAX-1, resulting in reduced energy costs.

Preventing Thermal Cracking

Benefits of well-atomized feed include rapid heat transfer to the feed for vaporization and uniform quenching of the catalyst as it passes through the flat sprays from the nozzles around the riser periphery. This rapid catalyst quenching minimizes local hot spots in the mix zone, preventing thermal cracking and yield degradation in the process.

Upgrade to Compete
ATOMAX-2 provides optimal yields and reduces energy costs

Current users of ATOMAX-1 technology can install ATOMAX-2 feed nozzle inserts in place of ATOMAX-1 inserts with no changes to the existing piping system or insert sleeve. Upgrades to ATOMAX-2 from other feed injection technologies are straightforward and seamless. Refiners can also receive ATOMAX-2 as a single module, making upgrading easy.

Maximize Yields Now

KBR turns visions into reality with our proven ATOMAX-2 feed nozzles. Together, we can design, install upgrade or optimize FCC solutions.

To learn more, visit: FCC.kbr.com or e-mail refining@kbr.com.

Low NOx Regeneration

Fluid Catalytic Cracking Technology

Proprietary design, compelling results

Our proprietary, counter-current regenerator design part of the KBR alliance with ExxonMobil produces lower NOx emissions than other types of regenerators by enabling a de-NOx reaction within the regenerator itself. For any given nitrogen feed, our regenerator produces 60 to 80 percent less NOx than others. This breakthrough technology provides refiners with a cost-effective solution to NOx abatement without post-treatment of FCC flue gas.

de-NOx in the Regenerator

From Grassroots to Revamps

Besides installing our technology in grassroots units, KBR has implemented counter-current technology in revamps of side-entry regenerators originally designed by other licensors. Performance in these revamps has achieved as much as 80 percent reduction in NOx.

Positive Reactions
In our regenerator, spent catalyst is evenly distributed across the top of the regenerator bed, causing a chemical reaction: 2 C + 2NO 2 CO + N2. Only 5 to 7 percent of the nitrogen in the coke escapes as NOx. The remainder converts to harmless N2 by the reaction with spent catalyst at the top of the regenerator bed. Only KBRs patented spent catalyst distributor can deliver these results. Benefits of this sytem include: Reduction of NOx emissions by 60 to 80 percent Proven, proprietary design Optimal catalyst bed density distribution Elimination of need for post treatment of FCC flue gas

KBRs counter-current regeneration design enables a de-NOx reaction within the regenerator itself.

Ready for Results?

KBR turns visions into reality with Low NOx Regeneration.Together, we can design, install, upgrade or optimize FCC solutions.

To learn more, visit: FCC.kbr.com or e-mail refining@kbr.com.

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