Grassroots FCC and Cyclofines™ Complete Successful Four Year Inaugural Campaign

Description:

Advancements in technology were incorporated by the KBR/Mobil design team in ExxonMobil's Altona Fluid Catalytic Cracking (FCC) unit, and resulted in a low cost, mechanically robust, and operationally friendly FCC unit. The new FCC unit, which was brought on line in late 1997, has improved the profitability of the Australian refinery by improving its conversion capability and crude diet flexibility. Emissions from the new FCC unit have been controlled by a Cyclofines™ third stage separator (TSS) system, which is the first of a kind. The grassroots Orthoflow™ FCC unit at ExxonMobil's Altona, Australia Refinery completed its very successful first run after four years on line. The unit's operation met all objectives including availability, capacity, and yields, through the end of the run, without any significant incidents or major mechanical issues. The FCC regenerator has operated well in both full and partial combustion modes. The turnaround inspection showed key technology components of the unit, including the ATOMAX-1TM feed nozzles, Closed Cyclones Riser Termination system, and CyclofinesTM third stage separator, to be in excellent condition, with only minimal wear. The Cyclofines™ third stage separator at Altona was the first grassroots application of the Cyclofines™ technology, and proved to be extremely robust in operation and in mechanical design. During its inaugural run the unit handled a wide range of catalyst loadings varying between normal operation and high loading events -- including at least one large catalyst carryover. After four years of service the Cyclofines™ unit showed no damage or measurable wear. Following the turnaround, it was returned to service without any maintenance or repair. The success of the inaugural campaign can be attributed to a collaborative team approach to design and operation. Refinery personnel and technical specialists in both ExxonMobil and KBR have supported design, start-up, and ongoing operation.