Anvil provides specific solutions to meet your FCC requirements.  We have helped clients optimize/revamp their existing facilities or install new process equipment for changing markets or product specifications. Our FCC project services include:

• Engineering - Conceptual through Detailed Design
• Procurement and Quality Inspection Services
• Constructability Planning and Reviews
• Pre-Turnaround, Startup, and Post Turnaround Planning
• Onsite Construction Coordination and Engineering Support

FCC Revamps

Identify market-driven opportunities and implement solutions; alleviate existing operating constraints, equipment reliability issues, process safety concerns, or mechanical integrity issues. Our FCCU revamp project experience includes:

• New Catalyst Coolers
• New Risers, Termination Devices, and Distributors
• New Stripper Trays and Rough-Cut Separators
• New Reactors and Main Air Blowers
• New Tertiary Separators
• New Main Fractionator/Recovery Compressor
• Absorber/Gas Plant Modifications
• Control and Safety System Upgrades

New FCC Facilities

Use our team's awareness and experience with the latest process equipment innovations and available licensed or developing technologies to develop solutions that are compliant with the latest environmental and process safety legislation requirements. Our experience with new FCC facilities includes:

FCCU Replacement

• New FCCU Reactors & Regenerators
• Main Air Blower
• Regenerator Cyclone Systems

Oxygen Enrichment, including:

• New Riser, Reactor, Catalyst Disengager, and Lift Air Blower
• New Catalyst Cooler
• Regenerator Upgrades

Convert an existing Exxon Model IV design FCCU to a UOP Pressure Balanced Unit. Project scope included replacing the Cold Wall Reactor with a Hot Wall Reactor and installing new Cyclones, new UOP Optimix Feed Nozzles, Catalyst Transfer System, Slide Valves, and Expansion joints.  The project also modified the Regenerator.

Anvil participated with the Client in their 5 stage Project Development Process-from early conceptual design through startup and provided the following services:

• Conceptual engineering and cost estimating services to evaluate multiple (18) project options
• Definition and detailed design services for the selected project
• Procure all equipment
• On-site Construction Coordination and Field Services during pre-turnaround, turnaround, and startup.

Project Highlights

• Turnaround focused execution and constructability planning to identify and mitigate risks to minimize impact
• World-wide sourcing for Reactor
• Laser Imaged the FCCU to ensure accuracy of design.

Revamp an existing FCCU by upgrading the Regenerator Cyclone System (4-sets hi-efficiency) and increasing the regenerator's tangent length by 10 feet.  Project also removed and replaced all refractory in the regenerator and replaced the Flue Gas Line, including the expansion joint.

Anvil participated with the Client in their 5-stage Project Development Process-from early conceptual design through startup.  Anvil provided the following services:

• Conceptual engineering and cost estimating services to evaluate multiple (15) project options
• Definition and detailed design services for the selected project, including Structural modifications for added load
• On-site Construction Coordination and Field Services during pre-turnaround, turnaround, and startup.

PROJECT HIGHLIGHTS

• Turnaround focused execution and constructability planning to identify and mitigate risks to minimize impact
• Constructability challenges included tight plot space and crane logistics and rigging
• Late decision to replace all refractory in the Regenerator

Modify an existing FCCU to handle alternate feedstocks using a Dual Riser System as designed by Kellogg, Brown, & Root.
Anvil provided the following services:

• Conceptual construction planning
• Definition and detailed design services for the selected project
• On-site Construction Coordination and Field Services during pre-turnaround, turnaround, and startup.

PROJECT HIGHLIGHTS

• Turnaround-focused execution and constructability planning to identify and mitigate risks to minimize impact

• Constructability challenges included tight plot space, crane limitations, and reactor size and weight limits resulted in 3 piece Reactor
• Modularized the Catalyst Cooler Structure and equipment to minimize erection time during the turnaround
• Designed thermosiphon steam system saving energy costs

PRE-TURNAROUND ACTIVITIES

• Installed refractory in the three Reactor sections
• Installed cyclones in the new top head assembly