Page 238 - Fluid Catalytic Cracking Handbook

CHAPTER 7

Project Management

and Hardware Design

Since 1942, when the first FCC unit came onstream, numerous
process and mechanical changes have been introduced. These changes
improved the unit's reliability, allowed it to process heavier feedstocks,
to operate at higher temperatures, and to shift the conversion to more
valuable products.
However, incorporating these changes in an existing unit is a major
project, usually more complicated than building a new unit. The two
critical components of a successful mechanical upgrade (or erection of a
new unit) are effective project management and proper design standards.
This chapter addresses project management aspects of a revamp. It
also provides design guidelines that can be used by a refiner in
selecting the revamp components. The original driving force for a
project is often a particular mechanical problem or a process bottle-
neck. The ultimate objective of a revamp should be a safe, reliable,
and profitable operation.

PROJECT MANAGEMENT ASPECTS
OF AN FCC REVAMP

The modifications/upgrades to the reactor and regenerator circuit are
made for a number of reasons: equipment failure, technology changes,
and/or changes in processing conditions. The primary reasons for upgrad-
ing the unit are improving the unit's reliability, increasing the quantity
and quality of valuable products, and enhancing operating flexibility.
The revamp (or erection of a new unit) requires successful execution
of each phase of the project:
• Pre-project
• Process design

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