Project Highlights
Client
ConocoPhillips Co.
Location
Lake Charles Refinery
Westlake, Louisiana
Mission
Upgrade/modernize FCC unit
Goals
- Increase production of more valuable liquid products
- Address catalyst circulation limits
- Maintain level of coke yield
- Provide flexibility for future changes in feed quality
Major Players
- UOP LLC – basic engineering/technology licensor
- Atkins Benham – detailed engineering
- Andrews FCC Consulting – consulting services
- Construction & Turnaround Services LLC – construction
- IAG – project management/procurement
Project Cost
- $5.9 million (reactor riser, regenerated catalyst standpipe, feed distributor replacement)
- $1.4 million (new external spent catalyst stripper)
Results
- Improved FCC catalyst circulation
- Increased conversion and improved yield selectivity
- Flexibility to process heavy aromatic feedstock
- Improved gasoline yield and conversion
- Greater reactor temperature control
- Reduced coke yield per expectations
This major overhaul of a fluid catalytic cracking (FCC) unit at the ConocoPhillips Lake Charles Refinery delivered increased conversion, improved yield selectivity and reliability, and offered the flexibility to process heavy aromatic feedstocks.
About two and a half years before the scheduled turnaround, ConocoPhillips assembled a team of FCC specialists that included Andrews FCC Consulting, IAG and UOP. IAG provided single-point responsibility for meeting the goals of the project across technology, engineering, procurement and construction.
With an approach focused on teamwork, all FCC unit processing objectives for the revamp were met, resulting in a turnaround that:
• Maintained conversion and improved the value of the FCC yield slate when processing a more aromatic feedstock with improved feed distribution and spent catalyst stripping technology
• Addressed catalyst circulation and stripping efficiency, providing additional unit flexibility
• Did not increase stack emissions.
ConocoPhillips found that the team approach produced innovative technical solutions. The project’s success illustrates both the value of assembling a specialized project team early and having single-point responsibility to ensure continual focus on objectives and schedule.