AM-02-54 MODERN DESIGN AND TROUBLESHOOTING TOOLS CREATE A SUCCESSFUL FCC REVAMP

Description:

Based on a refiner’s need for increased conversion and selectivity for propylene production, UOP revamped an existing UOPTM Stacked FCC unit to include OptimixTM feed distributors, VSSTM riser disengaging, and a modern reactor stripper design. The new reactor internals were sized for an increased feedrate, but the existing reactor shell had to be retained to maintain a constant structure and foundation load. Internal clearances were closer than would typically be used for a new reactor system. New internals were installed in the existing reactor stripper. The post-revamp operation has exceeded the process performance for propylene yield represented for the revamp. However, catalyst containment in the reactor was not as good as represented. A joint Risk Management plan was developed by OMV and UOP to identify all possible causes of the problem, establish the necessary means to allow for safe continued operation with the higher catalyst losses and the increased risk of erosion, and develop a long term solution.