The feed injectors of a fluid catalytic cracking (FCC) unit are a crucial component in providing the desired yield performance in the FCC process. Lummus Technology has raised the bar with a technological upgrade to our existing FCC feed injector line up — our new Micro-Jet FlexTM feed injectors.
This next generation FCC feed injector provides a host of performance benefits, including reducing droplet size, lowering pressure drop, accelerating feed vaporization and increasing a unit’s range of operation. The Micro-Jet Flex system also addresses operational challenges such as feed circuit hydraulics, steam usage and the cost of retrofitting existing hardware.
The Micro-Jet Flex feed injectors optimize all aspects in the feed injector system. With thorough contact of the feed and catalyst across the entire riser cross-section, the system incorporates a customized endcap design, three-stage atomization, optimal exit velocity and efficient use of steam. These system features help achieve higher production of valuable light olefins, aromatics and fuels when compared with conventional feed injectors they replace.
Retrofits
If you already have an FCC feed injector system in place, an update to your program is within reach. With only a change to some internal components of the injector body, our next generation Micro-Jet Flex feed injectors are the easiest decision you can make. The injector nozzle sizing is consistent with your current system, and there are no changes to your existing oil and steam side piping and flanges, or the existing sleeves/nozzle on the riser. We simplify the process to upgrade the performance of your existing FCC or RFCC risers, even if you have competing injectors.Consider Micro-Jet Flex feed injectors during your new construction planning or retrofitting phase to improve your operating performance and boost refinery margins.
Features and Benefits
Reduced droplet size and improved uniform distribution span
- Improves conversion
- Increases yield of valuable light products (e.g., gasoline, LPG)
- Reduces dry gas yield
- Accelerates feedstock vaporization
- Improves catalytic cracking, reduces thermal cracking
Reduced oil-side pressure drop
- Offers ability to process higher feed rates
- Overcomes hydraulic limitations of FCC fresh feed circuit
- Reduced delta coke and regenerator dense phase temperature
- Helps increase cat/oil ratio
- Supports additional conversion
Optimized injector tip velocity
- Minimizes catalyst attrition and nozzle erosion
- Minimizes service and operational issues
Optimized system design including injector angle, three-stage atomization and preconditioning of catalyst in the riser
- Provides complete contact of the feed and catalyst across entire riser cross-section
- Significantly reduces lift steam requirement
- Reduces thermal deactivation of the catalyst
Easily retrofitted into existing FCC and RFCC units
- Installs efficiently within typical maintenance turnaround schedules
- Pays for itself in less than a year