Case Study | Tackling Extreme Working Conditions — FCC Reaction–Regeneration System
Fluid Catalytic Cracking (FCC) is one of the most critical secondary refining processes in modern petrochemical plants. It converts heavy oil into high-value light oil products and chemical feedstocks. The core of this process is thereaction–regeneration system, where hot Catalyst Particles contact feedstock in the riser reactor to form light oil vapors. The coked catalyst is then sent to the regenerator for burning and reactivation before being cycled back into operation.
The system also includes the fractionation section, absorption–stabilization section, and flue gas energy recovery unit — all essential for improving product yield and energy efficiency.
The Harsh Reality: High Temperature, High Pressure, Catalyst Wear & Severe Corrosion
In FCC units, valves operate under extremely demanding conditions. Traditionally, many refineries relied heavily on imported brands such as:
Neles (Finland) – Ceramic Ball Valves
MOGAS (USA) – Metal-seated Ball Valves
KITZ & NBV (Japan) – High-performance metal-seated valves
But these valves often suffer from:
Catalyst erosion
High-temperature corrosion
Coking & blockage
Sticking and torque increase
Short service life
Case 1 – Sinopec Refining Subsidiary
As the core production unit of the refinery, its FCC system demands exceptional reliability from valves—resistance to High Temperature, pressure, erosion, and corrosive media.
The refinery had long used MOGAS metal-seated Ball Valves, yet repeated failures occurred due to:
High-temperature catalyst erosion
Internal scuffing and deformation
Coking leading to sticking and seizure
Maximum service life: < 1 year
After switching to KOWOV ceramiC Valves, the valve service life increased to: 3 years — a 3× improvement.
Case 2 – Shaanxi Yanchang Energy Chemical Company
As a coal-oil-gas integrated chemical enterprise, its FCC unit plays a key role in producing light oil products.
Adopting a strategy of “imported brands as primary, domestic high-end as supplement,” the company conducted long-term comparison tests between:
Imported Neles ceramic ball valves
Domestic KOWOV ceramic ball valves
Results:
Both achieved 18+ months service life
KOWOV reduced procurement cost by 40–50%
Delivery time shortened from 4–6 months → 1–2 months
Spare parts inventory cost reduced 50%
Failure response time reduced 60%
Overall O&M cost reduced 50%
Domestic substitution was gradually implemented across the plant.
Case 3 – Another Sinopec Petrochemical Base
This major refining complex previously relied on KITZ and NBV metal-seated ball valves for key FCC sections, including:
Reaction–regeneration system
Fractionation section
Flue gas power recovery unit (FGRU)
After switching to KOWOV ceramic valves, the results were:
Valve procurement cost reduced ≈35%
Spare parts turnover rate increased 40%
Average maintenance cycle shortened 30%
Ceramic Valve Adoption: Transforming FCC Reliability & Cost Efficiency
FCC is a cornerstone of fuel production and petrochemical feedstock supply. As China advances toward refining–chemical integration, green & low-carbon operations, and smart manufacturing, the role of high-performance valves becomes increasingly critical.
The rise of domestic ceramic valve technology — represented by KOWOV — is accelerating:
Localization
Reliability improvement
Cost reduction
Intelligent operation
Long-cycle, stable FCC production
High-end ceramic valves are becoming the new standard for demanding FCC applications.