Fluid Catalytic Cracking Unit

1. Fresh Feed

Problem: Maximize yield when injecting feed oil. 

Best practice: Leading providers of FCCU riser technology supply proprietary feed injection systems with nozzles designed specifically for superior feed stock injection and extended wear life. These systems deliver the optimal drop size and spray  distribution to increase cracking  efficiency and yield. 


2. Bio-Oil Injection

Problem: Inconsistent performance and reduced yield caused by nozzle wear. 

Best practice: Use injectors that allow adjustment of feed rates, prevent feed polymerization and feature specially-designed wear-resistant nozzles.

3. Torch Oil

Problem: Safety issues such as CO2 build-up,  mechanical issues in the regenerator during start-up and feed outage conditions caused by incomplete  torch oil combustion.

Best practice: Use OptiMax™ injectors with patented technology for thorough mixing of the oil and steam.  The injector produces uniformly sized small drops and consistent spray coverage to ensure complete combustion. 

4. Main Fractionator Water Wash

Problem: Corrosion and salt in the overhead line and downstream equipment.

Best practice: Continuous wash water injection to prevent or remove corrosive build-up. Injectors with WhirlJet® hollow cone and FullJet® full cone spray nozzles are widely used. The nozzles produce small- to medium-sized drops and uniform coverage. Also, use Computational Fluid Dynamics (CFD) to determine the optimal dispersion, coverage and injector placement for corrosion prevention. 

5. Emergency Quench

Problem: Quick and efficient cooling during upset conditions.

Best practice: Use injectors specially-designed for use  with steam for quick cooling without wetting and damage  to refractory-lined ducts. FloMax® S spray injectors atomize water with steam and produce small drops that evaporate quickly and completely. 

6. Slurry Recycle

Problem: Process disruption caused by equipment wear. 

Best practice: se high-flow steam atomized injectors, constructed of special  alloys that resist wear caused by slurry abrasiveness. OptiMax injectors are designed for durability for efficient, continuous recycling.

7. Regenerator Shell Cooling

Problem: Hot spots that damage metal refractory shells.

Best practice: Use strategically-placed steam nozzles that provide rapid cooling. FloMax® S nozzles use steam to atomize the water and produce consistently-sized small drops that provide quick cooling without wetting. 

For more information contact one of our Spray Specialists Contact Us