Figure 2 FIT G-Series feed injector
exceeding 4,5 million BPSD, the feed injection technolo- gy’s proprietary FIT G-Series (see Figure 2 ) was imple- mented into the design to efficiently atomise feed for rapid vapourisation – crucial for catalytic cracking. The feed injectors are designed for mechanical reliability, featuring simple internals to prevent plugging and erosion, with many nozzles lasting more than a decade without major repairs. The system optimises energy use to create fine oil mist droplets, ensuring maximum riser coverage and effective oil-catalyst mixing. This promotes rapid heat transfer and vapourisation, minimising coke and gas production. The robust design, using special metallurgy and advanced coatings, withstands the harsh riser environment, offering improved gasoline yields of 2 to 8 liquid vol%. The riser termination device, including the proprietary Linear Disengaging Device (LD2) – as for the RFCC ANCAP revamp case – and the proprietary Riser Separation System (RS2), represents a significant advancement in FCC tech - nology. These devices ensure rapid separation of catalyst and gas, preserving reaction products and preventing over-cracking. LD2, with its efficient catalyst-gas separa - tion and direct gas flow to reactor cyclones, minimises dis - ruptions by maintaining riser hydrodynamics. Its compact design integrates seamlessly into existing systems, reduc- ing catalyst carryover and ensuring low pressure drop for efficient operation. LD2 demonstrates reliability without unit upsets or ero- sion, while RS2 offers a three-dimensional solution with enhanced gas containment and larger diplegs for improved stripping. Ideal for new units and high-capacity revamps, RS2 maintains high collection efficiency and low pressure drop, enhancing operability and reliability under upset con- ditions. Its radial geometry reduces thermal stress, while the inertial separation principle provides superior mechan- ical reliability. Together, these devices improve process performance, operability, and mechanical reliability, making them valuable components in FCC units. The catalyst stripper packing technology, utilising high-efficiency structured packing, significantly enhances liquid product recovery in FCC processes. This technology not only boosts product yields but also reduces coke forma- tion, leading to lower regenerator temperatures and higher
catalyst circulation rates, thereby improving yield selectiv- ity. Benefits include improved hydraulic stability, enhanced hydrocarbon recovery, reduced steam usage, lower regen- erator oxygen demand and temperature, increased FCC capacity and efficiency, and more than a decade of reliable operation without fouling or plugging. Figure 3 (left) New LD2, reactor cyclones and stripper packing installed. Figure 4 (right) New FIT G feed injectors The catalyst stripper packing technology, utilising high- efficiency structured packing, significantly enhances liquid product recovery in FCC processes Hardware modifications The following technological improvements were imple- mented, as shown in Figures 3 and 4 : • Feed injectors were replaced with impact-type injectors, which require less steam for operation. • Stripper packing was installed in the reactor stripping section, significantly reducing the amount of hydrocarbon molecules that are dragged and burned in the regenerators as coke. • The ballistic separation system was replaced with an LD2 semi-cyclonic separation system.
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PTQ Q1 2026
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