Case Studies

Customer: W. R. Grace & Co.

Project: Davison Circulating Riser (DCR) Pilot Unit - Mark IV

Project Description:
Since signing a license agreement with W. R. Grace & Co.-Conn. to design and build the Davison Circulating Riser (DCR) FCC Pilot Unit in the late 1980’s, Zeton has delivered twelve DCR Pilot Units for customers worldwide. And from the very first unit, delivered to British Petroleum in London, England in 1989, Zeton has worked closely with Dr. Gordon Weatherbee of Grace to make process and operability improvements to the DCR Pilot Unit as part of our ongoing commitment to provide the very latest pilot plant technology to customers.

The latest Mark IV DCR Pilot Unit incorporates over three years worth of product development by Zeton’s engineering group in Canada, under the leadership of Chris Brown and Sean Murray. The first stage in the evolution of the Mark III DCR Pilot Unit to the Mark IV design involved a step change in control system technology, with the (now obsolete) Azonix control hardware being replaced with the state-of-the-art Honeywell HC900 Hybrid Controller and the Proficy – iFIX HMI software from GE Fanuc. The second stage involved the redesign of the relief system to comply with latest industry requirements for fire case design (via a customer-led HAZOP study), and the addition of positioners on the pressure control valves for significantly improved control of system pressure.

The third and final stage was the most radical of all – the redesign of the Mark III process layout from the ground up, from the structural steel frames to the major process equipment. The new Mark IV process layout, developed with input from Dr. Gordon Weatherbee of Grace and our customers, offers significant improvements in the operability and maintenance of the DCR Pilot Unit, while simplifying installation effort and time at the customer’s site. Two additional benefits of the new layout are that it will more readily accommodate future expansion or modification of the DCR Pilot Unit, and, once completed, it will fit inside a standard 40’ high cube shipping container for ocean shipment anywhere in the world. And, because the new layout requires less manufacturing labour to assemble, we are able to streamline the manufacturing process -- a win-win situation for our customers and Zeton!

For more information on the Mark IV DCR Pilot Unit, please contact Herman Bottenberg at Zeton in The Netherlands, or David Edwards and Adam Whalley at Zeton in Canada.

Technical Specifications:

Oil Feed rate 150-1600 ml/hr
Maximum operating pressure 3.2 barg (46.4 psig)
Maximum Riser temperature 650 deg. C
Maximum Regenerator Temperature 750 deg. C
Maximum Stripper Temperature 590 deg. C
Minimum Stabilizer Temperature -10 deg. C
Catalyst Charge 2500-3500 g
Davison Circulating Rate 2500-10000 g/h
Material of construction 316, 321 SS

Special Features:

  • Small overall height for easy installation into laboratory space
  • Slide valves control catalyst circulation from the regenerator and stripper similar to most commercial FCC units
  • Spent and regenerated catalyst can be sampled during normal operation
  • Material balances are calculated over a 30 minute period
  • State-of-the-art computer control system and HMI interface
  • Catalyst circulation rate is continuously monitored and displayed on the LCD display

Customer Quote

“The Mark IV design represents a major step forward in evolution of the Davison Circulating Riser pilot unit. The ergonomics of the unit have been considerably improved as a result of the new equipment and skid layout, and the additional of positioners on the pressure control valves along with the new state-of-the-art control system has significantly improved overall system performance” Gordon Weatherbee, W.R. Grace.