Fluid catalytic cracking (FCC) is the workhorse of modern crude oil refinery. Its regenerator plays a critical role in optimizing the overall profitability by efficiently restoring the catalyst activity and enhancing the heat balance in the riser reactor. Improvement in the device metallurgy and process operations have enabled industrial regenerators to operate at high temperatures with better a coke burning rate and longer operating cycle. Today, the carbon content of regenerated catalyst has drastically reduced to less than 0.1 wt.%. However, the unit is still plagued with operational complexities and insufficient understanding of the underlying dynamic, multiscale intricacies. Recent process-intensification strategies provide insights into regenerator performance improvement potentials. In this review, the importance of the uniform distribution of spent catalysts through structural modification and operational manipulations of the catalyst distributor is discussed. The knowledge of the role of baffles in enhancing excellent gas–solid interaction has been increasing, but skepticism due to its complex hydrodynamic effects on gas–solid flows fends off operators from its application, a critical evaluation of its implication in the regenerators is covered. The understanding of the contribution of air/steam distributor design and feed gas injection techniques for even contact with spent catalyst leading to the improvement in FCC performance is also investigated. The reliability of FCC components is a big concern, as unplanned shutdown and enormous economic losses are being witnessed due to device failure. To this end, mitigation approaches to damaging afterburn and high-temperature erosion problems with respect to process control and geometric adjustment in the bed, freeboard, cyclone separators and collection ducts are explored. Emission limits for fluid catalytic cracking unit (FCCU) and products are consistently ratcheting downward; the commingled turnkey solutions to reducing pollutants generation are also reviewed.
