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FCCFluid Catalytic Cracking Solutions

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CB&I’s FCC Design

Flexibility, Reliability and Performance

CB&I is an industry leader in licensing proprietary process technologies to the hydrocarbon industry worldwide. As the licensor of over 70 processes, CB&I knows the entire hydrocarbon value chain and how the various units are interconnected, leading to highly efficient and flexible designs.

CB&I offers the Lummus Fluid Catalytic Cracking (FCC) process that is based on 60-plus years of research and development and operating experience from multiple licensed units worldwide. The flexible FCC design delivers superior yields while processing a wide range of feedstocks, including challenging heavy feedstocks. Each design incorporates the most technically advanced hardware to meet today’s demands for ease of operation, longer run-lengths, lower operating costs, and state-of-the-art safety systems.

MAXIMIZE PROFITABILITY FOR TODAY’S DYNAMIC MARKETPLACE

FEED FLEXIBILITY

▪ Heavy residue ▪ Vacuum gas oils ▪ Coker gas oils ▪ Hydrotreated feedstocks

PRODUCT FLEXIBILITY

▪ Light olefins—ethylene/propylene/butylenes

▪ High octane gasoline ▪ Diesel ▪ Combination of above

PROVEN ADVANTAGES

▪ Superior yields ▪ Lower capital cost ▪ Lower operating costs ▪ Safe, efficient, and stable operation ▪ Mechanical reliability ▪ Inherent flexibility

PROPRIETARY FCC TECHNOLOGY

FEATURES• ModGridTM Catalyst Stripper

• Micro-JetTM Feed Injectors

• Reaction Termination Device (RTD)

• MSOTM Combustion Air Distributor

• IndmaxSM FCC Process

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ModGridTM Catalyst Stripper

Efficient Catalyst and Steam Contact

CB&I offers the innovative ModGrid catalyst stripper to improve the performance and flexibility required to meet the demands of today’s marketplace. The ModGrid stripper is a novel hardware design commercially proven to increase unit profitability. The unique, patented configuration provides a cost-effective and reliable solution for all modes of operation. The modular construction allows for easy installation through existing manways.

Design and Technology Features

▪ Baffles are assembled and built as modular grids ▪ Surface area is maximized for mass transfer

between catalyst and steam ▪ Channeling, bypassing, back-mixing

and dead spots are eliminated ▪ Catalyst takes a 360° turn as it flows down

the stripper, improving radial mixing

Commercial Experience

CB&I replaced conventional stripper internals with proprietary ModGrid stripper internals, enabling the client to increase the fresh feed throughput by 12% and to reduce the stripping steam rate by 30% while significantly improving gasoline and LCO yields. The improvements are shown in Table I.

Advantages

▪ Reduced dry gas and delta coke ▪ Reduced regenerator temperature— provides capability to increase feed

rate and/or process heavier feeds ▪ Higher catalyst-to-oil ratio ▪ Increased conversion and yield of light products ▪ Reduced steam consumption ▪ Highly attractive return on investment - typically measured in weeks

360O OF TRAVEL

ROBUST CONSTRUCTION

EXCELLENT FLUIDIZATION

EFFICIENT MASS TRANSFER

IMPROVED RADIAL MIXING

UNIFORM AND THOROUGH CONTACT

TABLE I

Post Revamp Result

Feed Rate, % +12

Stripping Steam, % -30

Gasoline Yield, wt% +0.90

LCO Yield, wt% +1.40

Dry Gas Yield, wt% -0.90

Coke Yield, wt% -0.45

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Micro-JetTM Feed Injectors

First Contact is Key

CB&I’s Micro-Jet feed injectors achieve superior yields of valuable light products when they replace conventional injectors. Micro-Jet feed injectors are designed with the optimal angle, correct exit velocities, and thorough feed/catalyst contact necessary to maximize the performance of the unit. Every injector is spray tested before installation.

Commercial Experience

CB&I’s Micro-Jet feed injectors replaced conventional technologies and demonstrated the post-revamp improvements shown in Table II.

Design and Technology Features

▪ Proprietary Micro-Jet injector tip design ▪ Flat fan spray pattern ▪ Uniform feed contact with catalyst ▪ Optimal exit velocity minimizes erosion

and catalyst attrition ▪ Low oil-side pressure drop ▪ Robust and durable

Advantages

▪ Provides high liquid yields and selectivity ▪ Instantaneously vaporizes the feed ▪ Minimizes thermal cracking to produce less dry gas

and delta coke ▪ Reduces feed pumping operating costs ▪ Lower dispersion steam rate reduces utility costs ▪ Nozzle performance maintained even at low

turn-down rates

TABLE II

Refinery A Refinery B

Riser Outlet Temperature,oF -9.9 +4.9

LPG, vol% +1.7 +2.8

Gasoline, C5– 430oF, vol% +1.3 +4.5

Conversion, vol% +2.1 +4.4

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Reaction Termination Device (RTD)

Enhanced Product Recovery

CB&I incorporates the patented Direct-Coupled Cyclone technology as the Reaction Termination Device (RTD) in grassroots and revamp applications. The RTD is critical in preserving the yields of gasoline and light olefins by terminating the reactions at the end of the reactor riser.

Design Features and Benefits

▪ Primary cyclone operates at a lower pressure than the containment vessel, causing the net flow of gases to be upwards and the blowdown of product vapors downwards to be negligible

▪ Nearly 100% recovery of the product vapors at the end of the riser ▪ Post-riser residence time is minimized to eliminate non-selective cracking

and hydrogen transfer reactions that degrade valuable products ▪ Significant reduction of delta coke and dry gas yield ▪ High liquid and light olefin yields ▪ Decreased hydrocarbon loading in the spent catalyst stripper

MSOTM Combustion Air Distributor

Ultra-Stable Flow

CB&I provides air distributors that include the unique Multi-Stage Orifice (MSO) nozzle designed to provide ultra-stable flow. Through extensive CFD modeling, CB&I has identified the erosion mechanisms often seen in conventional borda tube nozzles. The proprietary MSO nozzle design stabilizes the air flow in the nozzle and minimizes localized catalyst siphoning and subsequent erosion. This design is commercially proven and offers multiple improvements in regenerator operation.

Design features and benefits

▪ Increased reliability ▪ Uniform combustion ▪ Lower after-burn ▪ Reduced NO

X emissions

▪ Decreased catalyst deactivation ▪ Ability to operate at low excess O

2

Riser

NegativePressureCyclone

NegativePressureCyclone

P1 < P2

Stripper Gas

P1 P2

400

300

200

100

0

-100

Axial Velocity (ft/sec)Distributor Wall

Conventional Borda Tube—Jet is Unstable New MSO Design—Ultra-Stable Jet

Distributor Wall

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IndmaxSM FCC Process

Increased Propylene/Light Olefins Production

The Indmax(1) process, developed by Indian Oil Corporation Limited’s (IOCL) R&D Center, is a breakthrough in FCC technology for converting heavy feeds (including residue) selectively to propylene and other light olefins. CB&I is the exclusive licensor for the marketing and design of Indmax FCC units worldwide.

The Indmax FCC process combines the advanced hardware of the Lummus FCC process with the unique, multi-functional proprietary catalyst formulation and process concepts developed by IOCL to achieve exceptionally high conversion and selectivity to propylene/light olefins. The process is highly flexible and is able to optimize a broad range of products for any given market scenario—a key to maximizing profitability.

Design and Technology Features

▪ Multifunctional, low delta-coke catalyst with high metals tolerance ▪ Advanced hardware design and know-how of Lummus FCC technology ▪ Proven design and operating strategy to achieve maximum conversion and selectivity to olefins ▪ Enhanced olefins recovery ▪ Lower capital and operating costs

Advantages

▪ Maximum olefins yield (over 50% C2-C

4 olefins)

▪ Inherently flexible process (maximize propylene/propylene plus gasoline/propylene plus ethylene) ▪ High selectivity to olefins (over 45% propylene in LPG, 50% ethylene in dry gas) ▪ Proven process to convert heavy residue to light olefins

The Indmax process was commissioned by IOCL in 2003 at their Guwahati Refinery in Assam, India. This unit processes residue feed with a CCR of approximately 4 wt%. The unit has been running smoothly since start-up, making products with the desired specifications.

Two larger units designed by CB&I are currently in various stages of detailed engineering and construction. One of the units, with a capacity of 85,000 BPSD, is scheduled to start-up in early 2014.

(1) Indmax is a service mark of Indian Oil Corporation

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EPC Capabilities

A Single Source of Responsibility

Drawing upon its comprehensive worldwide resources, CB&I can provide complete licensing, design and EPC services on FCC projects anywhere in the world. Projects range from single technology revamps to grassroots construction of new units. Company culture sets a high standard for safety, quality and productivity. CB&I’s experience enables us to meet very tight schedules. On one revamp, the whole project—from technology selection to oil-in—was accomplished in less than five months. Lummus designed grassroots FCC units constructed by CB&I have started up quickly and smoothly. These units embody technology features that provide superior yields, longer run-lengths, and ease and flexibility of operation. They are easy to control, with stable catalyst circulation and efficient catalyst regeneration. Plus, each design provides the flexibility a refiner needs to meet the demands of today’s volatile market.NOT F

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A World of Solutions Visit www.CBI.com

CB&I is a leading provider of technology and infrastructure for the energy industry. With over 125 years of experience and the expertise of more than 40,000 employees, CB&I provides reliable solutions to our customers around the world while maintaining a relentless focus on safety and an uncompromising standard of quality.

Corporate OfficePrinses Beatrixlaan 352595AK The Hague, NetherlandsTel: +31 70 373 2010

Worldwide Administrative OfficeOne CB&I Plaza2103 Research Forest DriveThe Woodlands, Texas 77380-2624, USATel: +1 832 513 1000

Only employees, agents or representatives authorized under and pursuant to written agreement with CB&I are authorized to distribute this brochure to an actual or potential client of CB&I. ©Copyright 2016 by Chicago Bridge & Iron Company. All rights reserved. Printed in USA. 23M092013H 6-0 05.03.16

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