FCC Manufacturing

Custom FCC valves for maximum safety and performance

Delta Controls designs and manufactures FCC slide valves as well as other FCC service and isolation valves capable of withstanding the extreme operating conditions inside Fluid Catalytic Cracking units. Whether exposed to erosive catalyst flows, high temperatures or severe mechanical loads, our FCC valves are engineered for long-term, reliable performance.

We deliver custom-engineered valves for both reactor and regenerator circuits, fully tailored to your specific process conditions and installation layout. By executing engineering, machining, cladding, refractory application and final assembly entirely in-house, we ensure short lead times and full control over quality and performance.

Delta Controls is also able to design and manufacture like-for-like replacement valves fully in accordance with customer specifications. Supported by our experienced engineering team, we produce both proprietary Delta Controls designs and reverse-engineered solutions for existing installations. This allows us to reproduce, optimize or adapt existing valves on a one-to-one basis, without requiring major modifications to the surrounding installation. The result is maximum flexibility, reduced delivery times and a reliable replacement for existing OEM solutions.

What we manufacture

Our FCC production scope includes, among others:

• Slide valves for regenerator, flue gas and catalyst lines
• Plug valves, butterfly valves and gate valves for FCC applications
• Turnkey valve–actuator systems, including hydraulic and electro-hydraulic drives
• Retrofit replacements for existing OEM models with custom-engineered successors
• Valves equipped with advanced purge systems, sealing concepts and valve seats

Each valve is engineered in close cooperation with your process team or turnaround contractor, ensuring a perfect fit on site and full alignment with your operational objectives.

Engineering and workmanship down to the finest detail

Delta Controls operates a fully equipped manufacturing facility where FCC valves are produced in accordance with the highest technical standards:

• 3D design, CFD flow analysis and strength calculations
• Cladding of critical wear areas (e.g. Stellite, Inconel)
• Refractory application, curing, stress relieving and heat treatment
• Precision machining and tolerance control to customer specifications
• Testing at temperature and pressure with full documentation

Our FCC valves are designed for long service life and minimum maintenance intervals, even under the harshest FCC conditions.

Replacement or upgrade of existing FCC valves

Many FCC units still operate with older-generation slide valves or obsolete OEM designs that are difficult to maintain or replace. Delta Controls offers:

• Retrofit designs based on original dimensions and performance requirements
• Modular upgrades (e.g. new seats, sealing systems, actuator interfaces, refractory improvements)
• Complete documentation, 3D models and test certificates

Whether your installation is equipped with valves from Z&J, TapcoEnpro, IMI Remosa, or legacy manufacturers such as Kubota, Chapman or Houston Systems, we can replace, upgrade or further develop your existing solution.

Why FCC valve production by Delta Controls?

• Over 45 years of experience with FCC valves worldwide
• All capabilities under one roof: engineering, machining, cladding, refractory and testing
• Brand-independent approach with tailor-made solutions for every OEM type
• Perfectly matched valve–actuator combinations with plug & play installation
• Full support during engineering, manufacturing and commissioning