CASE STUDY
FCC EXPANDER
SOUTH KOREA
FCC EXPANDER
The FCC Expander operators were
experiencing severe vibration due to catalyst
fines sticking on the rotating blades resulting
in a shutdown every six weeks, on average.
After Therma-Chem Treatment
Figure 1 shows the daily average vibration
level of the four vibration probes on the
expander for the prior year before using
Therma-Chem. Treatment with Turbo-Mor
commenced in October 2013 and Figure 2
reflects the first year of treatment. There were
no high vibration trips for the next 30 months
of operation. This presented a significant
saving for the plant.
Figure 1

Figure 2


Vacuum Tar Residue
and Fuel Gas Fired Boiler
Japan
High flue gas temperatures
and APH corrosion

HFO Fired Boiler
Saudi Arabia
Poor boiler efficiency and high
CO2 emissions

Coal Fired Boiler
Romania
Loss of boiler efficiency and
high CO2 emissions

Gas and HFO
Fired Boilers
Egypt
Efficiency loss due to fouling on
superheaters and economiser

Expander in FCC Unit
South Korea
Catalyst deposits on rotating
blades causing severe vibration

Shipping – LNG Tanker
Malaysia
Heavy deposits on combustion
and radiant sections of boilers
as well as back-end corrosion
Process Heater
Belgium
Heater temperature limited
due to fireside conditions
Process Heater
Singapore
Radiant temperature and
heater duty limited by fouling
Gas Fired Reformer
UK
Unsustainable flue gas
temperature increase
due to fouling
Refinery
Western Europe
Pre Shutdown Cleaning to
neutralized sulphur deposits