Replacement of the FCC air blower
- The challenge
Resolving a key operational issue with financial significance
- The solution
A tailored temporary installation delivered in record time
- The impact
Production continuity and strengthened trust
Client:Petroineos
Location:Lavéra, France
Sectors:Petrochemical and refining
The challenge
Resolving a key operational issue with financial significance
Petroineos, a trusted partner since 2017, faced a major challenge when the air blower of the FCC (Fluid Catalytic Cracking) unit at the Lavéra site broke down.
This blower, which had not failed in 35 years, is essential for catalyst regeneration. Its malfunction temporarily halted the unit’s operation, directly impacting the site's profitability. The FCC unit is central to the upgrading process, transforming low-value products into high-value fuels and derivatives.
Beyond this immediate loss, throughput in other units had to be reduced, leading to an overall drop in site production.
In this context, every hour counted: the urgency to find a fast and reliable solution was critical to avoid significant financial losses.
The solution
A tailored temporary installation delivered in record time
The project was carried out over two months, beginning with a three-week consultation and clarification phase. During this time, we worked closely with Petroineos to fully understand the technical requirements and define the best approach.
Faced with a critical situation, Aggreko designed and deployed a turnkey compressed air solution in record time.
- Precise sizing: Two flow rate scenarios were anticipated to adapt to the unit’s operating modes.
- Compressor mix: A combination of Stage V electric and diesel compressors was selected based on fleet availability, optimising performance while reducing fuel consumption and emissions.
- Large-scale installation: 32 compressors, 2 MX2 Stage V generators, and 4 600 kVA generators were mobilised to ensure a continuous and secure air supply.
- Once the scope was validated, we moved into the delivery and installation phase, which lasted one month. This included logistics coordination, on-site works, and system integration. The final week was dedicated to testing and commissioning, ensuring full operational readiness and optimised performance.
The implementation posed both logistical and technical challenges: - Limited space to install such a large number of machines
- Maintaining stable production despite a critical minimum flow threshold
- Managing an outlet pressure lower than the minimum operating pressure of our compressors, requiring a specific innovation: the use of orifice restrictions to maintain optimal back pressure
- Compliance with strict safety standards, including integration with the site’s automatic shutdown system
Beyond the technical aspects, success relied heavily on human commitment. Aggreko teams worked in rotating 8-hour shifts to ensure continuous monitoring of the installation – including supervision, maintenance, fuel management, and troubleshooting. This constant presence ensured the reliability of the system throughout the project duration.
Aggreko was selected for this project based on the lower consumption and emissions of its equipment, its competitive commercial offer, and the trusted relationship established with the client site since 2017. Drawing on proven practices and experience from previous projects, we developed a bespoke solution for Petroineos, tailored to the specific challenges of the Lavéra site.
This strategic approach enabled smooth execution and reliable performance.
The impact
Production continuity and strengthened trust
Thanks to Aggreko’s rapid response, the FCC unit remained operational for 45 days, avoiding a prolonged shutdown that could have led to significant financial losses.
Petroineos not only safeguarded its revenue but also ensured continuity across its production chain.
Customer feedback was unanimously positive, highlighting the quality of collaboration and Aggreko’s ability to quickly mobilise both technical and human resources to respond to the emergency.
Key learnings for future projects
This project helped strengthen Aggreko’s expertise for similar interventions:
- The importance of maintaining a robust stock of spare parts
- The need to plan for 24/7 operations (3x8h shifts) from the outset
- Anticipating the use of subcontracted labour
- The value of relocating backup equipment locally to enable rapid response
- Internal development to now offer warm air solutions, better suited to certain processes