Fluid Catalytic Cracking (FCC) Optimization

FCC oxygen enrichment can provide refineries with additional flexibility to overcome bottlenecks to improve plant efficiency. The addition of a controlled flow of gaseous oxygen into the combustion air main increases the coke-burning capacity of the regenerator and provides a reliable, low cost option for achieving capacity or conversion increases while avoiding significant capital outlays or unit modifications.

Safety is paramount. Air Products can provide safety and control equipment specifically designed for refinery needs. We can work with you to design flowrate control so that a safe amount of oxygen is delivered to match the equipment requirements.

Oxygen enrichment of an FCC can be done year round or seasonally based upon temperature or fuel demand patterns.

Expand Fluidized Catalytic Capacity and Conversion with Oxygen Enrichment

FCC oxygen enrichment can provide the following process benefits

Helps to overcome air blower capacity limitation

The addition of oxygen to the combustion air offers a practical solution to increasing the capacity of a blower-limited catalytic cracker

Overcomes regenerator velocity limitation

Reduction of air blower rate followed by the addition of oxygen can increase the capacity of a velocity-limited catalytic cracker

Improves yield

Higher oxygen level in the regenerator air improves coke removal and thereby increases the yield of the higher value light-end products

Helps to maintain capacity on a seasonal basis

Higher oxygen level in the combustion air can counter the problem of reduced FCC capacity when high ambient temperatures and humidity decrease air blower output

Reduces flue gas velocity

Addition of oxygen helps to minimize regenerator vapor velocity, which can help increase production without the additional catalyst loss or cyclone erosion normally associated with higher throughput.

Increases time between turnarounds

Lower gas velocity reduces wear and tear on FCC's cyclones

Improves temperature control

A well-designed oxygen flow control system can allow for simple and precise adjustments for changes associated with day-to-day FCC operation

Helps to overcome operational feedstock challenges

Higher oxygen concentration in FCC can increase temperature when lighter feedstocks are used or it can help with handling extra carbon formed on the catalyst in the regenerator when heavier feedstocks are used

Services for Your FCC Oxygen Enrichment Operation

Air Products can provide the necessary equipment, technology and services:

Feasibility studies – conduct a technical evaluation of your FCC operation and recommend the level of oxygen required for your desired capacity increase and the best mode of supply
Engineering – design and build an oxygen flow control system tailored to your operation
Start-up support – provide oxygen safety training, P&ID review of oxygen flow control system, and hands-on training on how to operate the flow controls

Need help determining if oxygen can help your refining process?

Air Products is always here to help you assess your FCC operation with a technical evaluation to show you the level of oxygen required for your desired capacity increase.