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FCCU Revamps – Challenges, Opportunities, and Lessons Learned

Presented By

Subhash Singhal - KNPC

Ahmed Al-Harbi - KNPC


FCCU revampsIn order to improve refinery performance by reducing fuel oil make, FCC revamp was envisioned to process heavier feeds and maximize conversion unit utilization. The other objective was to enhance safety and reliability for the unit to achieve a cycle length of four years. KNPC has executed a successful FCC revamp project where the company scouted different technological options and selected UOP supplied state-of-art technology like VSS, Elevated feed nozzles and advance stripper. 

The project scope included replacement of reactor and provision of elevated feed nozzles, VSS and advanced stripper. An auxiliary air blower was added to meet the air deficit during heavier feed processing. The fractionator was provided with four numbers of packed beds for a lower pressure drop and not to revamp the wet gas compressor. For reliability enhancement the hot wall standpipes, flue gas line, and orifice chamber were replaced with cold wall along with slide valves. Limited modifications were carried out in Gas Con section.

Mr. Ahmed Al-Harbi is a Senior Process Engineer and handles key responsibility for optimized operation of the FCC complex. Mr. Al-Harbi has more than 20 years of experience in process engineering.

Mr. Subhash Singhal is a Technical Specialist with 30 years of experience in Refinery and petrochemicals. He joined KNPC in 1994 and has worked in different process functions handling FCC/HCR/CCR/MTBE/ALKY/HP Units and CFP Project from FEED to detailed engineering stage. Mr. Singhal has also been involved in establishing a Research and Technology Department in KNPC.

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