Axens offers benchmark RFCC technology for traditional gas oil cracking and residue cracking. The R2R™ technology was originally developed by Total as a cost-effective, flexible and reliable means to profit from market opportunities. This advanced R2R resid FCC technology is offered to the market place through the FCC Alliance between Axens (technology developer and licensor), IFP Energies Nouvelles (R&D), Total (operations expertise) and Technip Stone & Webster Process Technology (licensing and engineering innovation). Proven innovative technology elements developed by the FCC Alliance and other partners have combined to bring our customers the best available technology.
Important innovations have been developed by Axens in all phases of the technology: feed pre-treatment, Residue FCC reactor technology, two-stage catalyst regeneration, distillate operation, high propylene production, product recovery and product & effluent treatment.
Key advances incorporated in the design include:
- Best available feed injector technology
- Riser temperature control with MTC
- Catalyst mixing control with SCM technology
- RS2 high containment riser separation system
- Vapor quench technology for high severity operation
- Superior catalyst stripping with structured packing
The Axens R2R process provides yields that are unmatched in the industry with the flexibility to process a wide range of feedstocks – from gas oil through residue – in the same unit to meet multiple product scenarios (max distillate, max gasoline, or max light olefins)
The patented R2R configuration with two-stage catalyst regeneration for residue feedstock minimizes catalyst deactivation in the presence of metals to maintain higher activity with more metals on the catalyst, thereby reducing catalyst replacement costs. The two-stage scheme also rejects a substantial portion of the regeneration heat as CO in the partial-burn first stage. When additional heat removal for heavier feedstock is required, a widely proven and reliable dense-phase catalyst cooler can be added.
The Axens design reflects the combined expertise of the Alliance members to offer lower capital, operating, and maintenance costs as compared to competing technologies. To date, Axens and Technip Stone & Webster Process Technology have designed over fifty grassroots RFCC & FCC units. These units have achieved more than 200 years of proven commercial operation in processing over 2 million BPD of feedstocks ranging from gas oils to heavy residues.
A New Separator Helps FCC Adapt to a New Refinery-Petrochemical Role