Fluid Catalytic

www.kbr.com
2007 Kellogg Brown and Root LLC
All Rights Reserved
Printed in U.S.A.

Cracking

070114 08/07
K08077

Unsurpassed innovation,
performance and reliability

www.kbr.com/technology

Fluid Catalytic Cracking

Since 1990, KBR has designed more than a dozen FCC

units and revamped more than 160 FCC units worldwide
Meeting Todays Challenges
Refiners today face the choice of purchasing
light sweet crudes at a premium price or
investing in bottom-of-the-barrel upgrading.
Yet with stringent environmental
requirements and a dwindling supply of
quality crudes, upgrading is the logical
solution to remain competitive.

Frontrunner in FCC
Not only are we a recognized leader in
FCC, but we also pioneered the technology
in the late 1930s. This led to a KBR and
ExxonMobil joint venture alliance in the
design, construction and operation of
the worlds first commercial FCC unit at
ExxonMobils Baton Rouge, Louisiana
refinery in 1942. It also marked the
beginning of a solid partnership with
ExxonMobil in FCC technology that
remains today.

Refinery ROI

At the ExxonMobil FCC project in Altona, Australia, KBR proved that FCC solutions
offer long term reliability and low capital costs.

Our FCC experts hold industry-leading

experience in designing, engineering,
procurement and construction services.
We evaluate modifications to increase
capacity, improve and maximize product
yield and enhance on-stream factor and
mechanical reliability.

Our experts can help clients:

Accelerate ROI, ROCE, RONA
and cash flow

Overcome resource
constraints

Design, engineer, construct

and service FCC units

Identify new opportunities for

improvement

Increase profitability

Revamp and replace

technology

Achieve cost objectives

Reduce safety incidents

Extend the life of FCC

investment

Sustain benefits
Stay current with
environmental regulations

Fluid Catalytic Cracking

KBRs Technology Center (KBRTC) contains numerous pilot plants, analytical

laboratories and pilot plant fabrication facilities and a talented staff of
engineers, chemists, specialists and craftsmen who develop and
commercialize new and improved process technologies.

Long-Term Reliability
Rigorous testing, ongoing research, catalyst evaluation,
feedstock characteristics and product yield assessment
make KBR a cut above. With KBR, our clients count on
unmatched FCC solutions that are low in capital cost and
high on quality, long-term reliability and operability.

Rigorous
testing,
ongoing
research,
catalyst
evaluation,
feedstock
characteristics
and product
yield
assessment
make KBR a
cut above.

Technical Services
Following start up of the unit as well as during normal
operation, technical service engineers assist refiners
in gaining maximum value from investment in KBR
technology through routine refinery visits and consultation.
We maximize clients ROI using our licensed technologies
through technical services for operations and turnarounds.

Lower Capital Costs

Our joint engineering teams developed the KBR
Orthoflow FCC process technology, which includes
the compact, self-supporting Orthoflow converter and
combines the disengager, stripper and regenerator vessels
into a single vessel.
This unique design minimizes the cost of construction,
and also reduces the amount of field mechanical work and
required plot space.

Fluid Catalytic Cracking

KBR provides testing, training and process

controls to help meet refinery objectives
FCC Advanced Process
Controls
KBRs Advanced Process Control
(APC) is especially beneficial for
FCC units due to their complexities
and large number of interactive
variables. Our APC system
consists of:

Severity Control
Combustion Control
Pressure Balancing and Control
Fractionator Control
Vapor Recovery Unit
(VRU) Control

APC gets you closer to targets

and constraints, improves stability
and makes operation seamless.
This translates to enhanced
operational information and
faster responses to changes
in refinery objectives.

Operator Training Simulator

Successful start-up of grassroots
FCC units is dependent on a
well-trained operations team.
To ensure your team is ready for
anything, KBRs operator training
simulator provides a realistic
dynamic simulation of the FCC
process configured to resemble the
actual FCC operator interface.
KBRTC specializes in cold flow modeling
the simulation of process characteristics at
near ambient temperatures and pressures.
Creating realistic cold flow models is a unique
talent and KBR is a leading practitioner of this
technique.

Advanced technology
allows KBRs operators
to simulate all aspects
of plant operations and
controls, as well as
startups, shutdowns
and emergencies.

Quick, Safe & Effective Revamps

KBRs approach to revamping draws upon unrivaled skill in all aspects of FCC
technology. For fast-track implementation of the latest technology improvements,
KBR and our industrial fabrication and construction partner, InServ, provide
lump-sum turnkey revamp and turnaround solutions that include:

Increased capacity and conversion

Greater feedstock flexibility

Gasoline yield improvement

Octane improvement

Light olefins yield optimization

Closer integration with other refinery operations

Improvements in reliability, maintainability, environmental

compliance and on-stream time

Fluid Catalytic Cracking

Leading-edge technology and service

that spans 100 years

Fluid Catalytic Cracking

Design solutions. Optimize processes.

Enhance productivity. Accelerate ROI.
Why Wait?
KBR turns visions into reality with our proven FCC technologies and advanced features
from our alliance partner ExxonMobil. Together, we can design, construct and optimize
FCC solutions.

MAXOFIN

Offers the ability to adjust propylene yield, propylene/ethylene ratio and olefins/
liquid fuels ratio as market conditions demand

ATOMAX-2 Feed Nozzles

Produces 43 percent smaller droplet size than the leading industry ATOMAX-1
nozzles, and developed by KBR in cooperation with ExxonMobil

Riser Quench Technology

Improves gasoline yield and octane, and prevents over-cracking that result in
undesirable products

Closed Cyclone Riser Termination

Minimizes dry gas make and increases gasoline yield using a simple compact
cyclone system

DynaFlux Stripping Technology

Reduces entrained hydrocarbons by 80 percent compared to conventional stripper

designs and may achieve six percent or less hydrogen in the coke

CycloFines Third Stage Separator

Meets particulate emissions regulations, extends downstream turbine blade life,

offers higher turbine efficiency and less FCC downtime

Low NOx Regeneration

Provides Low NOx emissions and uniform combustion in the regenerator bed,
minimum flue gas afterburning and less catalyst deactivation

REGENMAX

Reduces regenerator emissions and entrainment and provides clean catalyst

burning under partial CO combustion at minimum investment

Dense Phase Catalyst Cooling

Offers the most reliable Catalyst Cooler that provides complete flexibility in the
regenerator

To learn more, visit: FCC.kbr.com

or e-mail refining@kbr.com.

MAXOFIN

Maximizing Light Olefins

Refineries and petrochemical plants are finding it difficult to keep pace
with the increasing worldwide demand for propylene. Historically,
steam crackers have satisfied this demand through co-product
propylene but now the supply is lagging demand. As more steam
crackers use ethane feedstock and produce little propylene, there is
an increasing need for processes that produce large quantities of
propylene with less ethylene co-product.
The MAXOFINTM FCC process offered by KBR and ExxonMobil fills
this niche and helps refiners stay competitive by combining a high
ZSM-5 content additive with KBR proven OrthoflowTM FCC hardware.
This combined technology maximizes propylene production from
conventional FCC feedstocks while producing much less ethylene than
would result from traditional steam cracking.

Enhanced Flexibility

Refiners now have an easy and

flexible means of adjusting propylene
production, propylene/ethylene ratio
and olefins/fuels ratio as market
conditions dictate.

Refiners today require a technology that can respond to market

demands. KBRs MAXOFIN can produce 20 wt% or more propylene from
FCC feedstocks, yet still maintain the flexibility to produce fuels when
market demand shifts. When the margin between propylene and fuels
is low, the MAXOFIN FCC can operate as a conventional FCC to produce
mostly gasoline, and when the demand of propylene is relatively high,
the process can maximize propylene at the expense of gasoline. If
markets require distillate and propylene, our MAXOFIN FCC process
allows refiners to run the primary riser at low conversion to preserve the
distillate yield. Light naphtha and C4s formed in the primary riser can
be recycled at more severe conditions in the second riser to maximize
conversion of these components to propylene. Besides processing FCC
recycle streams; the high severity second riser can also accept naphthas
and C4s from elsewhere in the refinery complex, such as coker naphtha
and C4s. Paraffinic naphthas, such as light straight run, can receive an
upgrade in the MAXOFIN unit to increase octane of the straight run
naphtha while adding to the units propylene yield.

To learn more, visit: FCC.kbr.com or e-mail refining@kbr.com

Fluid Catalytic Cracking Technology

Keeping Pace with Rising Demand

for Propylene

MAXOFIN

Economic Factors to Consider

While naphtha yield is limited in the high severity
propylene operating mode, octane and BTX content
of the MAXOFINTM FCC naphtha product is improved
greatly relative to that from a conventional FCC unit.
In addition to the BTX, refiners can economically
recover ethylene produced by the MAXOFIN
FCC process for use as high value petrochemical
feedstock. The process also allows refiners to
upgrade lower-valued naphtha streams that do not
fit into more lucrative product blends produced by
the refinery.

Boost Product Value Now

High Value Products from MAXOFINTM FCC.

Maximizing high value propylene and other

petrochemicals from FCC operations will only occur
with an on-purpose technology. With KBRs MAXOFIN FCC, refiners
can achieve greater propylene yield while maintaining product
flexibility to remain competitive in changing markets.

To learn more, visit: FCC.kbr.com or e-mail refining@kbr.com

Fluid Catalytic Cracking Technology

Produce the Molecules You

Want with Minimum Byproduct

DynaFlux S tripping Technology

Safeguard Reactor Products

Upgrades to FCC units typically increase catalyst circulation which
elevates stripper catalyst flux rates.This increase significantly reduces
stripper efficiency by entraining hydrocarbon product gases into
the regenerator. Once entrained, regenerator temperatures rise
requiring the stripper to use additional combustion air while more
hydrocarbon product is burned and lost.

Managing Flux Rates

Top down
cross section view

KBR DynaFlux stripping technology addresses two challenges

seen in conventional strippers: high local catalyst flux and
poor lateral mixing. Developed jointly by KBR and ExxonMobil,
DynaFlux technology allows the FCC stripper to
effectively manage elevated flux rates. DynaFlux
consists of three main components: two-stage stripping,
the Flux Tubes proprietary baffle and Lateral Mixing
Elements (LME) that increases the mean catalyst
residence time, minimizing flow short-circuiting while
improving mixing.

Reducing Hydrocarbons, Increasing Circulation

With KBR DynaFlux,

refiners can expect lower
regenerator temperature,
increased catalyst
circulation and higher
conversion.

Many FCC units employ a two-stage stripper, but

when coupled with our DynaFlux technology, unstripped
hydrocarbons are reduced by up to 80 percent. Once a specific,
critical flux rate is passed, stripper efficiency plunges and
flooding occurs. Flux Tubes extend the operating range of the
stripper to prevent flooding and provide a significant efficiency
gain without increasing stripper diameter.

Save the Hydrocarbons

KBR turns visions into reality with our proven DynaFlux
stripping technology. Together, we can design, install, upgrade
or optimize FCC solutions.

To learn more, visit: FCC.kbr.com or e-mail refining@kbr.com.

Fluid Catalytic Cracking Technology

Greater efficiency,
enhanced performance

CycloFines Third Stage Separator

Flue gas from

regenerator

FLOW

Clean flue
gas

Achieving Environmental Requirements

Now refiners can meet environmental requirements
with CycloFines Third Stage Separator system. KBRs
CycloFines uses patented technology and a proprietary
design to remove catalyst fines from FCC flue gas. The
maximum allowable particulate emission at the stack
dictates the level of separation required and CycloFines
offers the highest efficiency of its type.

Proven Experience
Developed by ExxonMobil and KBR in an extensive
joint effort that began in 1993, CycloFines offers refiners
improved abatement technologies to comply with
environmental particulate requirements. CycloFines
technology was first commercialized for environmental
protection in September 1997 at the ExxonMobil refinery
in Altona, Australia.

Low Cost, High Benefit

Catalyst fines

CycloFines extends downstream turbine

blade life and helps achieve higher
efficiency with less FCC downtime. Our
solution also protects flue gas expander
turbines from erosion caused when
catalysts in flue gas exit the regenerator.

Our low-cost, high-benefit solution is capable of achieving

less than 50 mg/Nm3 particulates in flue gas and lower
stack opacity. CycloFines demonstrates ultra-high efficiency
during normal usage, but also an operational robustness
during upsets in the FCC regenerator operation. Our improved
solution essentially captures all particles larger than five
microns in diameter.

Comply Today
KBR turns visions into reality with CycloFines Third Stage
Separator. Together, we can design, install, upgrade or
optimize FCC solutions.

To learn more, visit: FCC.kbr.com or e-mail refining@kbr.com.

Fluid Catalytic Cracking Technology

High-efficiency, robust
abatement solution

Closed Cyclone Riser Termination

Maintain Desired Yields

Rapid removal of product vapors from FCC converters after
riser cracking is paramount to maintaining desired yields. Our
Closed Cyclone Riser Termination system, developed jointly by
KBR and ExxonMobil, consists of interconnecting ductwork that
routes product vapors directly into secondary cyclones and out
of the converter. Unlike some competing systems, our proven
system is the market-leading solution to preserving desired
product.

Powerful Solution, Unrestricted Heat Up

Our Closed Cyclone Riser Termination system is mechanically
robust and provides improved catalyst retention. Refiners using
our technology can expect reduced vapor residence time that
significantly minimizes post-riser thermal cracking. This system
essentially eliminates dilute phase catalytic cracking and
improves coke selectivity. Yield benefits include less dry gas,
less butadiene, less bottoms and more gasoline.
Reliable, market-leading riser termination
system with lower risk of catalyst
carryover.

Prevent Thermal Cracking

Closed cyclone technology is a simple solution for improving
yields for revamp applications. The interconnecting ductwork
to close cyclones in the FCC reactor/disengager is readily
adaptable to existing cyclone systems. Refiners using our
closed cyclone solution can reduce counter-productive effects
of thermal cracking and extract enhanced FCC yields.

Enhance Yields Now

KBR turns visions into reality with our proven Closed Cyclone
Termination solution. Together, we can design, install, upgrade
or optimize FCC solutions.

To learn more, visit: FCC.kbr.com or e-mail refining@kbr.com.

Fluid Catalytic Cracking Technology

Market-leading solution
to enhanced yields

ATOMAX-2 Feed Nozzles

Maximum Coverage = Outstanding Yields

Achieving optimal yields from your FCC unit is heavily dependent
on the feed injection system providing both rapid vaporization and
intimate contact between the oil and catalyst. This optimization is
where KBR excels. Our ATOMAX-2 feed nozzles, developed by KBR
in cooperation with ExxonMobil, produce an approximately 43 percent
smaller droplet size than the industry-leading ATOMAX-1 nozzles.

Accelerating Value While Reducing Energy Costs

Our ATOMAX-2 feed nozzles provide at least five times more droplets
in any given volume, and better coverage of the riser cross section by
maintaining a flat, fan-shaped spray pattern. Using ATOMAX-2, refiners
can expect a more uniform atomization across the spray. Refiners
receive an added benefit of a 10 to 15 percent lower pressure drop
than ATOMAX-1, resulting in reduced energy costs.

Preventing Thermal Cracking

Benefits of well-atomized feed include rapid heat transfer to the feed for
vaporization and uniform quenching of the catalyst as it passes through
the flat sprays from the nozzles around the riser periphery. This rapid
catalyst quenching minimizes local hot spots in the mix zone, preventing
thermal cracking and yield degradation in the process.

Upgrade to Compete
ATOMAX-2 provides optimal yields and
reduces energy costs

Current users of ATOMAX-1 technology can install ATOMAX-2 feed

nozzle inserts in place of ATOMAX-1 inserts with no changes to the
existing piping system or insert sleeve. Upgrades to ATOMAX-2 from
other feed injection technologies are straightforward and seamless.
Refiners can also receive ATOMAX-2 as a single module, making
upgrading easy.

Maximize Yields Now

KBR turns visions into reality with our proven ATOMAX-2 feed nozzles.
Together, we can design, install upgrade or optimize FCC solutions.

To learn more, visit: FCC.kbr.com or e-mail refining@kbr.com.

Fluid Catalytic Cracking Technology

Advanced design,
superior performance

Low NOx Regeneration

de-NOx in the Regenerator

Our proprietary, counter-current regenerator design part

of the KBR alliance with ExxonMobil produces lower NOx
emissions than other types of regenerators by enabling a
de-NOx reaction within the regenerator itself. For any given
nitrogen feed, our regenerator produces 60 to 80 percent
less NOx than others. This breakthrough technology provides
refiners with a cost-effective solution to NOx abatement without
post-treatment of FCC flue gas.

From Grassroots to Revamps

Besides installing our technology in grassroots units, KBR
has implemented counter-current technology in revamps of
side-entry regenerators originally designed by other licensors.
Performance in these revamps has achieved as much as 80
percent reduction in NOx.

Positive Reactions
In our regenerator, spent catalyst is evenly distributed across the
top of the regenerator bed, causing a chemical reaction: 2 C +
2NO 2 CO + N2. Only 5 to 7 percent of the nitrogen in the coke
escapes as NOx. The remainder converts to harmless N2 by the
reaction with spent catalyst at the top of the regenerator bed.

KBRs counter-current regeneration

design enables a de-NOx reaction
within the regenerator itself.

Only KBRs patented spent catalyst distributor can deliver these

results. Benefits of this sytem include:
Reduction of NOx emissions by 60 to 80 percent
Proven, proprietary design
Optimal catalyst bed density distribution
Elimination of need for post treatment of FCC flue gas

Ready for Results?

KBR turns visions into reality with Low NOx Regeneration.Together,
we can design, install, upgrade or optimize FCC solutions.

To learn more, visit: FCC.kbr.com or e-mail refining@kbr.com.

Fluid Catalytic Cracking Technology

Proprietary design,
compelling results

Fluid Catalytic

www.kbr.com
2007 Kellogg Brown and Root LLC
All Rights Reserved
Printed in U.S.A.

Cracking

070114 08/07
K08077

Unsurpassed innovation,
performance and reliability

www.kbr.com/technology

Fluid Catalytic Cracking