Fluid Catalytic Cracking Unit (FCCU) - China Petroleum Chemical Equipment Network

Fluid Catalytic Cracking Unit (FCCU) — изображение 2

Установка каталитического крекинга в псевдоожиженном слое (УФ-ККС)

Core Equipment

Riser reactor Regenerator Special fractionation tower for catalytic cracking Main air blower and flue gas turbine High-temperature heat exchanger and air cooler High-temperature slide valve and plug valve

Riser rapid reaction and short residence time technology High-efficiency catalyst regeneration and coke burning technology Deep catalytic cracking technology for heavy oil Flue gas energy recovery and energy conservation technology Anti-heavy metal pollution and anti-coking design High-temperature wear-resistant and anti-corrosion structural technology

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Product Introduction

Fluid Catalytic Cracking Unit (FCCU) is a crucial secondary processing unit in modern oil refineries, playing a key role in converting low-value heavy oil fractions into high-value light products. Its main feedstock is vacuum gas oil (VGO), a heavy distillate from the atmospheric and vacuum distillation unit. The core principle relies on a fine zeolite catalyst, which promotes the cracking of long-chain hydrocarbon molecules into shorter, more valuable ones under high-temperature and fluidized bed conditions.

The unit mainly consists of a riser reactor, disengager, stripper, and regenerator. Preheated VGO is injected into the riser, where it contacts hot regenerated catalyst and undergoes instant cracking. Vapors of light products are separated from the catalyst and sent to fractionation, while spent catalyst (deactivated by coke deposition) is stripped and then regenerated by burning off coke with air, restoring its activity and providing heat for the reaction.

Key products include high-octane gasoline, olefin-rich LPG, light cycle oil (diesel component), and heavy cycle oil. FCCU significantly improves refinery economic efficiency by maximizing light product yield and serves as a vital source of feedstock for downstream petrochemical processes, making it the “heart” of fuel-oriented refineries.

Types and Characteristics of Equipment

Type

Equipment Type: Riser-type Fluid Catalytic Cracking Unit (FCC), a core reaction equipment for secondary processing in oil refineries.

Features

Converts heavy distillate oil and residual oil into high-value gasoline, liquefied petroleum gas (LPG) and light diesel oil.Adopts coaxial / parallel structure of reactor and regenerator, featuring high thermal efficiency and small footprint.Has strong feedstock adaptability to high-sulfur and heavy crude oils from the Middle East and Russia.Features large operating flexibility and long continuous operation cycle.Enables catalyst recycling and regeneration, with low energy consumption and high yield.Equipped with flue gas energy recovery to meet environmental protection requirements in overseas markets.

Установка каталитического крекинга в псевдоожиженном слое (УФ-ККС)

Fluid Catalytic Cracking Unit (FCCU) is a key secondary refinery unit that converts heavy oil into high-value gasoline and light olefins.

Установка каталитического крекинга в псевдоожиженном слое (УФ-ККС)

It uses zeolite catalyst in a fluidized bed to crack long-chain hydrocarbons into lighter, more profitable products.

Установка каталитического крекинга в псевдоожиженном слое (УФ-ККС)

FCCU features continuous catalyst regeneration and is widely regarded as the core unit for boosting refinery yields and profits.

Basic Principles and System Composition

Basic Working Principle

Under high temperature conditions, with the help of molecular sieve catalysts, macromolecular heavy oil undergoes cracking reactions and breaks down into light hydrocarbons such as small-molecule gasoline, diesel oil and liquefied petroleum gas. The deactivated catalyst after reaction is regenerated by coke burning and recycled.

Overall System Composition

Reaction System: Riser reactor, settler, stripping section Regeneration System: Regenerator, main air distribution system, catalyst circulation pipelines Fractionation System: Fractionation tower, overhead condensation system, mid-pump reflux, product extraction Energy Recovery System: Flue gas turbine, waste heat boiler, air preheater Stabilization System: Absorber, desorber, stabilizer for separating dry gas and LPG DCS Control System and Safety Interlock System

Basic Principles and System Composition

Preheated feed oil enters the riser, contacts high-temperature regenerated catalyst and reacts rapidly. Reaction oil and gas are separated from the catalyst; the oil and gas enter the fractionation tower and are separated into gasoline, diesel oil and slurry oil. Spent catalyst enters the stripping section, and after stripping out entrained oil and gas, is sent to the regenerator. Main air is introduced to burn off coke for regeneration, restoring catalyst activity. Regenerated catalyst returns to the riser for recycling. Regenerated flue gas is discharged after energy recovery, and qualified products are produced by the fractionation system.