Catalytic Cracker (FCC Units) — Asbestos Exposure Crosswalk
What This Equipment Is
A fluid catalytic cracker (FCC) is the centerpiece of most modern refineries — a continuously circulating system of fluidized catalyst that cracks heavy gas-oil feedstock into lighter, more valuable products (gasoline, propylene, butylene, fuel gas). The FCC operates at high temperature (typically 1,250–1,400°F in the regenerator) with circulating catalyst rates of hundreds of tons per minute.
Major FCC components include:
- Reactor — where vaporized feed contacts hot catalyst and cracks
- Regenerator — where coke-laden spent catalyst is burned clean
- Riser — vertical transfer pipe carrying feed and catalyst from regenerator to reactor
- Standpipes and slide valves — controlling catalyst circulation
- Main fractionator — separating cracked products
- Flue-gas system — recovering heat from regenerator flue gas (CO boiler, expander turbine, ESP)
Every hot surface in this system is heavily refractory-lined and externally insulated.
Asbestos Products Historically Used Around FCC Units
| Product Category | Where on the FCC | Notes |
|---|---|---|
| Refractory castable | Reactor, regenerator, riser internal lining | See Refractory Mortar |
| Refractory brick | Hot-face linings | See Refractory Brick |
| Block insulation | Vessel exterior insulation | Calcium silicate, magnesia |
| Slide-valve packing | Catalyst-flow control valve stems | Braided asbestos rope packing |
| Gaskets | All flanged process and instrument connections | Asbestos sheet, spiral-wound |
| Pipe covering | Hot piping (feed, products, flue gas) | Magnesia, calcium silicate |
| Removable insulation blankets | Around valves and frequently accessed sections | Sewn asbestos cloth + asbestos batting |
Why FCC Work Was a High-Exposure Activity
FCC turnarounds are among the largest refinery maintenance events — sometimes 30–60 days of round-the-clock work involving hundreds of contractors. The refractory tear-out alone (replacing eroded internal lining on reactor, regenerator, and riser) is a massive multi-week dust-generating operation. Slide-valve rebuilds, main-fractionator entry, and flue-gas system work all happen in the same window. The combined boilermaker / refractory-mason / pipefitter / insulator crews working in close quarters during an FCC turnaround share concentrated peak exposure.
Manufacturers Named in Litigation Involving FCC Components
- UOP (Universal Oil Products) — FCC technology licensor and equipment
- Kellogg Brown & Root (KBR) — FCC technology and design
- Standard Oil / Exxon Research — FCC technology lineage
- A.P. Green Refractories — refractory products
- Harbison-Walker Refractories — refractory products
- North American Refractories (NARCO) — refractory products
- General Refractories — refractory products
- Johns-Manville — insulation, refractory
- Garlock Sealing Technologies — gaskets and packing
- Crane Co. — valves
Documented Product References
Images sourced from publicly available product-identification reference materials. Inclusion does not constitute a finding of liability against any company.
Trust Funds That May Apply
- A.P. Green Industries Asbestos PI Settlement Trust
- Harbison-Walker Refractories / RHI Asbestos PI Trust
- North American Refractories Company (NARCO) Asbestos PI Settlement Trust
- General Refractories Asbestos PI Trust
- Manville Personal Injury Settlement Trust
- Garlock Sealing Technologies LLC Asbestos PI Trust
Trades Most Exposed at FCC Work
Refractory masons, boilermakers, pipefitters, insulators (Heat & Frost), iron workers, refinery turnaround contract crews, plant operators.
Jobsites in the Network
- Every Missouri refinery running FCC units
- See companion pages: Fired Heaters, Distillation Towers, Refractory Brick, Refractory Mortar
Compiled from publicly filed asbestos litigation, EPA / state-DNR records, and industry-publication histories. Product and company references reflect what has been alleged or documented in publicly filed litigation. This page does not constitute a finding of liability against any company. Not legal advice; consult a licensed attorney about your specific situation.