Page 16 - Fluid Catalytic Cracking Handbook

CHAPTER

Process Description

Fluid catalytic cracking (FCC) continues to play a key role in an
integrated refinery as the primary conversion process. For many
refiners, the cat cracker is the key to profitability in that the successful
operation of the unit determines whether or not the refiner can remain
competitive in today's market.
Approximately 350 cat crackers are operating worldwide, with a
total processing capacity of over 12.7 million barrels per day [1]. Most
of the existing FCC units have been designed or modified by six major
technology licensers:

1. ABB Lummus Global
2. Exxon Research and Engineering (ER&E)
3. Kellogg Brown & Root—KBR (formerly The M.W. Kellogg
Company)
4. Shell Oil Company
5. Stone & Webster Engineering Corporation (SWEC)/IFP
6. UOP (Universal Oil Products)

Figures 1-1 through 1-3 contain sketches of typical unit configura-
tions offered by some licensers. Although the mechanical configuration
of individual FCC units may differ, their common objective is to
upgrade low-value feedstock to more valuable products. Worldwide,
about 45% of all gasoline comes from FCC and ancillary units, such
as the alkylation unit.
Since the start-up of the first commercial FCC unit in 1942, many
improvements have been made. These improvements have enhanced
the unit's mechanical reliability and its ability to crack heavier, lower-
value feedstocks. The FCC has a remarkable history of adapting to
continual changes in market demands. Table 1-1 shows major develop-
ments in the history of the process.
The FCC unit uses a microspheroidal catalyst, which behaves like
a liquid when properly aerated by gas. The main purpose of the unit