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Catalytic Cracking

For expanded product flexibility, the FCC unit can be integrated with upstream units such as Mild Hydrocracking to balance the gasoline and distillate products, or downstream units such as Polynaphtha in order to offer higher flexibility toward targeted products (Gasoline, Diesel or Propylene).
Catalytic Cracking

Axens Offer

Axens offers state-of-the-art FCC technology for traditional gas oil cracking and residue cracking. This advanced technology has been brought to market through the efforts of a partnership between Axens (technology developer and licensor), IFP Energies nouvelles (R&D), Total (operations expertise) and TechnipFMC (engineering innovation).

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.

Select an application

When processing traditional distillate feeds or blends with a Conradson Carbon Residue (ConC or CCR) content less than around 2 to 3 wt. %, a single stage regeneration system operating in complete or partial combustion mode is generally adequate. 

Process Technologies

VGO FCC

The reaction system is the heart of the process and is defined from the point of catalyst introduction into the riser to the catalyst discharge from the stripper. The entire system needs to be designed to work in concert to maximize performance for maximum distillate, gasoline or LPG production.

Over 60 new FCC/R2R™ units have been licensed
Over 250 revamps have been performed
The refinery “money-maker"

Adsorbents

Adsorbents

Arsine Removal Adsorbents

The poisonous effects of arsine and other metal hydrides on hydrogenation and polymerization catalysts is well documented. By far the most common, arsine can seriously deactivate the high-activity Ziegler Natta, metallocene and noble metal catalysts used for processing cracked light ends.

Adsorbents

Drying Series Adsorbents

Water removal applications are widely encountered in the industry sector. Activated alumina and molecular sieves stand at the forefront of the several different materials available on the market.

Adsorbents

Mercury Removal Adsorbents

Mercury removal from hydrocarbons is crucial due to HSE-related issues, corrosion problems and downstream catalyst poisoning.

Adsorbents

Purification Series Adsorbents

Material specially developed to achieve your feedstock’s specification requirements.

Furnaces & Heat Recovery

CO Combustor and Waste Heat Boiler for Catalytic Cracking

CO Combustor and Waste Heat Boiler are key equipment considering the need for optimal operation of unit. Thanks to an extensive design experience with feedbacks from operators and a complete knowledge of this process, Heurtey Petrochem Solutions provides an unparalleled service such as these following features:

  • Lowest Emission (95%+ reduction with emission reduction technology) including Carbon Monoxide (CO)
  • Fully Modularized
  • Maximum Steam Production / Superheat Level
  • Off-line (no REGEN GAS) Steam Production
  • Optimum Cleaning of Heat Transfer Surface
  • Optimized Plot Plan

Consulting, Supply & Support

Consulting, Studies & Audits

Axens offers a customized approach, including tailored studies, audits and consulting services, covering technical and operational challenges.

Technical Support & Performance Management

Axens is fully committed to be your partner and provide assistance and support during your project lifecycle, from conception to start-up & running operations.

Digital Services & Applications

Axens' digital platform combines real-time data and digital solutions to optimize operations, reduce environmental impact, and lower costs while maximizing profitability. By delivering actionable insights and detailed performance reports, it enhances asset operation and performance for smarter, more efficient outcomes.

When processing residues containing high levels of metals (Ni, V and Na) and ConC values in excess of 3 wt.%, more sophisticated FCC designs are required. 

Process Technologies

R2R™

The Reactor-2-Regenerator (R2R™) design was developed to specifically meet the challenge of heavy resid processing.

The unique two-stage regeneration system permits safe regeneration of catalyst containing high levels of metals, principally vanadium that would otherwise rapidly deactivate the catalyst.

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
Over 60 new FCC/R2R™ units have been licensed
Over 250 revamps have been performed
Extremely resilient on a wide array of feedstocks

Adsorbents

Adsorbents

Arsine Removal Adsorbents

The poisonous effects of arsine and other metal hydrides on hydrogenation and polymerization catalysts is well documented. By far the most common, arsine can seriously deactivate the high-activity Ziegler Natta, metallocene and noble metal catalysts used for processing cracked light ends.

Adsorbents

Drying Series Adsorbents

Water removal applications are widely encountered in the industry sector. Activated alumina and molecular sieves stand at the forefront of the several different materials available on the market.

Adsorbents

Mercury Removal Adsorbents

Mercury removal from hydrocarbons is crucial due to HSE-related issues, corrosion problems and downstream catalyst poisoning.

Adsorbents

Purification Series Adsorbents

Material specially developed to achieve your feedstock’s specification requirements.

Furnaces & Heat Recovery

CO Combustor and Waste Heat Boiler for Catalytic Cracking

CO Combustor and Waste Heat Boiler are key equipment considering the need for optimal operation of unit. Thanks to an extensive design experience with feedbacks from operators and a complete knowledge of this process, Heurtey Petrochem Solutions provides an unparalleled service such as these following features:

  • Lowest Emission (95%+ reduction with emission reduction technology) including Carbon Monoxide (CO)
  • Fully Modularized
  • Maximum Steam Production / Superheat Level
  • Off-line (no REGEN GAS) Steam Production
  • Optimum Cleaning of Heat Transfer Surface
  • Optimized Plot Plan

Consulting, Supply & Support

Consulting, Studies & Audits

Axens offers a customized approach, including tailored studies, audits and consulting services, covering technical and operational challenges.

Technical Support & Performance Management

Axens is fully committed to be your partner and provide assistance and support during your project lifecycle, from conception to start-up & running operations.

Digital Services & Applications

Axens' digital platform combines real-time data and digital solutions to optimize operations, reduce environmental impact, and lower costs while maximizing profitability. By delivering actionable insights and detailed performance reports, it enhances asset operation and performance for smarter, more efficient outcomes.

The Petrochemical industry requires ever more propylene to supply the expanding chemicals and polymers markets. 

In order to address the general lack of propylene from steam crackers, dedicated propylene production technologies, Axens has developed a large portfolio of solutions to produce more propylene per barrel of crude oil: High Propylene FCC (HP FCC™), Resid to Propylene (R2P™), FlexEne™, HS-FCC™ (High Severity FCC) and Olicrack™.

Process Technologies

High Propylene FCC

Axens has developed High Propylene FCC (HP FCC™) for traditional distillate feeds to produce 10-15wt% propylene. Depending on the quality of the feed and the propylene and other product targets, Axens can develop customized solutions for:

  • Maximum LPG and Gasoline or "High Propylene"
  • Maximum Propylene
  • Maximum Distillate & LPG
Over 60 new FCC/R2R™ units have been licensed
Over 250 revamps have been performed

R2P™ (Resid to Propylene)

Axens has developed Resid to Propylene (R2P™) for residue feeds to produce 8-13 wt% propylene. When the process objective is maximum propylene production, specific technology features must be added to the FCC/RFCC unit. The challenge is particularly great when the feedstock contains residue.

Depending on the quality of the feed and the propylene and other product targets, Axens can develop customized solutions for:

  • Maximum LPG and Gasoline or "High Propylene"
  • Maximum Propylene

FlexEne™

Axens has developed the new FlexEne™ technology to expand the capabilities of the FCC process which is the main refinery conversion unit traditionally oriented to maximize gasoline and at times propylene production.

FlexEne™ is an innovative combination of two well-proven technologies: Fluidized Catalytic Cracking (FCC) and Oligomerization (Polynaphtha™). Combined in an innovative way, they can significantly improve product flexibility to control the balance of propylene, gasoline and diesel production with a low capital investment. This FLEXibility is achieved by selective oligomerization of light FCC alkENEs (olefins) for recycle cracking in the FCC.

By adjusting the catalyst formulation and operating conditions, the FCC process is able to operate in different modes: Maxi Distillate, Maxi Gasoline and High Propylene. This provides the product flexibility required by the market.

7 references for FlexEne™ recorded since its introduction
Proven Flexibility & Simplicity
High Return on Investment

HS-FCC™

An alliance involving Saudi Aramco, ENEOS, King Fahd University of Petroleum and Minerals, Technip Stone & Webster Process Technology and Axens Solutions has led to the development of the HS-FCC™ process which is able to produce up to 25 wt% propylene by converting heavy hydrocarbon feedstock under severe FCC conditions.

The main features of the HS-FCC™ process are:

  • A down-flow reactor
  • High reaction temperature
  • Short contact time
  • High catalyst to oil ratio (C/O)

The HS-FCC™ process operates at high temperature and high C/O ratio but with a short contact time in order to promote catalytic cracking, enhancing thus the yield of propylene.

Down-flow reactor
Higher reaction temperatures (550°C to 650°C) than conventional FCC units
Highly selective Catalyst

Olicrack™

Olicrack™ is a process to bridge the petrochemical-refinery gap to convert unwanted or lower valued olefins into propylene and ethylene. The process combines olefin Oligomerization and cracking in a single reactor using a selective zeolite catalyst and continuous catalyst regeneration system.

The purpose of the Olicrack™ unit is to produce a high quantity of propylene, through oligomerization and cracking of primarily C4 to C6 olefin-rich feeds, using a zeolite-based catalyst. The aim of the Olicrack™ process is to improve low value feedstocks such as off-gas, LPG purges or light ends through the production of propylene and, to some extent, ethylene.

Integrated: adapted to tight integration between refineries and petrochemical complexes
Flexible: cracked stocks from refineries and petrochemical plants can be co-processed
Robust system

Adsorbents

Adsorbents

Arsine Removal Adsorbents

The poisonous effects of arsine and other metal hydrides on hydrogenation and polymerization catalysts is well documented. By far the most common, arsine can seriously deactivate the high-activity Ziegler Natta, metallocene and noble metal catalysts used for processing cracked light ends.

Adsorbents

Drying Series Adsorbents

Water removal applications are widely encountered in the industry sector. Activated alumina and molecular sieves stand at the forefront of the several different materials available on the market.

Adsorbents

Mercury Removal Adsorbents

Mercury removal from hydrocarbons is crucial due to HSE-related issues, corrosion problems and downstream catalyst poisoning.

Adsorbents

Purification Series Adsorbents

Material specially developed to achieve your feedstock’s specification requirements.

Furnaces & Heat Recovery

CO Combustor and Waste Heat Boiler for Catalytic Cracking

CO Combustor and Waste Heat Boiler are key equipment considering the need for optimal operation of unit. Thanks to an extensive design experience with feedbacks from operators and a complete knowledge of this process, Heurtey Petrochem Solutions provides an unparalleled service such as these following features:

  • Lowest Emission (95%+ reduction with emission reduction technology) including Carbon Monoxide (CO)
  • Fully Modularized
  • Maximum Steam Production / Superheat Level
  • Off-line (no REGEN GAS) Steam Production
  • Optimum Cleaning of Heat Transfer Surface
  • Optimized Plot Plan

Consulting, Supply & Support

Consulting, Studies & Audits

Axens offers a customized approach, including tailored studies, audits and consulting services, covering technical and operational challenges.

Unit Revamps & Retrofits

You face many challenges, which include operating in a safe, reliable and environmentally sound manner while responding to changing markets dynamics.

Technical Support & Performance Management

Axens is fully committed to be your partner and provide assistance and support during your project lifecycle, from conception to start-up & running operations.

Digital Services & Applications

Axens' digital platform combines real-time data and digital solutions to optimize operations, reduce environmental impact, and lower costs while maximizing profitability. By delivering actionable insights and detailed performance reports, it enhances asset operation and performance for smarter, more efficient outcomes.

Explore some

Resources

Technical article

Technical Article - Guiding the crude-to-chemicals complex towards a net-zero future

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Insight

Maximizing the Production and the Transformation of Aromatics

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Insight

Targeting the Highly Coveted Olefins

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Insight

Two Conversion Routes to Maximize the Economic Returns of a Crude-to-Chemicals Project

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Insight

Maximizing the Production and the Transformation of Aromatics

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Insight

Targeting the Highly Coveted Olefins

Read more
Insight

Two Conversion Routes to Maximize the Economic Returns of a Crude-to-Chemicals Project

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Insight

Recommended Process Routes for Maximized Oil Conversion to Aromatics and Olefins

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Petrochemicals
Case Study

Case Study - Refining to olefins production

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Whitepaper

White Paper - Crude-to-Chemicals

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Technical article

Technical Article - Guiding the crude-to-chemicals complex towards a net-zero future

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Technical article

Technical Article - Maximize Refinery Profitability with Novel RFCC Technologies

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Technical article

Technical Article - Technology Advances Enable Crude To Chemicals Projects

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Technical article

Technical Article - Shale Gas Drives New Opportunities For US Downstream

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Press release

SOCAR's Heydar Aliyev Oil Refinery Signs License And Design Agreements With Axens For The Fluid Catalytic Cracking Unit

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Press release

Axens’ Technologies for HPCL Rajasthan Refinery in India

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Press release

Saudi Aramco, TechnipFMC and Axens advance Catalytic Crude to Chemicals technology

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Press release

Pertamina Licenses Axens Technologies for its Balikpapan and Cilacap Refineries in Indonesia

Read more

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