Advances in FCC reactor technology

The riser termination device and the feed distribution system are the key elements that enable FCC reactor technology to achieve the high performance demanded in the 1990s and beyond. UOP`s development efforts have combined cold flow modeling and commercial optimization testing to produce new technology in both areas. A key differentiation of the UOP feed-catalyst contacting system is the use of a catalyst acceleration zone to moderate density and achieve plug flow before feed injection. Commercial data confirm the benefit and importance of elevated feed injection and proper catalyst environment in this three-phase system. A new high-performance Optimix feed nozzle has been developed and cold-flow tested and is currently undergoing commercial demonstration. New riser disengagement technology with prestripping has been extended to internal riser FCC units. The new disengager design will achieve at least 98% hydrocarbon containment. Cold-flow modeling has confirmed catalyst separation efficiency, and the design has been accepted for two FCC reactor revamps scheduled for mid-1995 and for 1996.