A Novel High-Severity FCC Process for Enhancing the Production of Light Olefins

A. Maadhah 1*,T. Ino 2,H. Hamid 1,M. Abul-Hamayel 1,T. Okuhara 2,A. Aitani 1, A. Maghrabi 1
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The Research Institute, King Fahd University of Petroleum & Minerals, Dhahran, Saudi Arabia 2 Japan Cooperation Center, Petroleum, Toshima-ku, Tokyo 170-6058, Japan

Introduction The conventional FCC is being extended, using technology developed in Japan and Saudi Arabia, to a high-severity FCC (HS-FCC) to produce significantly more olefins and high-octane gasoline. The operating regime of this novel process is more severe and utilizes a special down-flow reaction system [1]. The process utilizes a downflow reactor and operates above 550C at a short contact time, high catalyst to oil ratio, and prevents back-mixing that yields undesirable by-products. Experimental Experiments were conducted in a downer-type pilot plant with a capacity of 0.1 bbl/d using hydrotreated vacuum gas oil (VGO) of Arabian Light origin. The pilot plant consists of a downer reactor, stripper, regenerator, and catalyst hopper. Feed oil is charged into the upper part of the downer reactor together with dispersion steam. Regenerated catalyst is also charged to the top of the reactor from the catalyst hopper. At the outlet of the downer, product hydrocarbons are separated immediately from catalyst in the stripper, where heavy oil adsorbed on the spent catalyst is stripped by steam, and then spent catalyst is sent to the regenerator. All tests were conducted at 600C and a catalyst/oil ratio of 40. The base catalyst was a low activity USY FCC catalyst supplied by CCIC, Japan. The catalyst was modified with 10wt% ZSM-5 additive (supplied by Grace, USA). The yields of light olefins, gasoline, light cycle oil and coke make are presented in Table 1 [2]. The base catalyst yielded about 29wt% light olefins and 45wt% gasoline. In the case of ZSM-5 addition, the yield of light olefins increased to more than 37%, particularly propylene which showed an increase of 72%. The results showed that ZSM-5 is highly selective toward propylene relative to Y-Faujasite containing base catalyst. The rise in light olefins was accompanied with a drop in gasoline yield since the addition of ZSM-5 accelerates the cracking of gasoline to lighter products. The addition of ZSM-5 is effective in catalytic systems where the base catalyst have low hydrogen transfer activity. The yield of light olefins for the base catalyst (with and without ZSM-5) increased with increasing conversion. Comparative Economics The economics of the upgraded refinery has been evaluated using the relative internal rate of return (IRR) at prevailing prices of the second quarter of 1998. Both refineries were assumed at a location in the Arabian Gulf coast, with a capacity of 200,000 bbl/day each processing Arabian Light crude oil. The capacity of the conventional and HS-FCC units in both refineries was 36,000 bbl/day. The

economics of the upgraded refinery has been evaluated as an incremental economics from the base refinery. Incremental investment and IRR of propylene and para-xylene recovery are listed in Table 2. Incremental investment has been calculated from the difference in investment costs and the difference in returns between the two HS-FCC cases. The results showed that the HS-FCC case would give more profitability to the refinery. In both HS-FCC cases, the IRR reached 17 to 18%, while large investment is required to expand capacities of propylene, MTBE, and alkylation units. If para-xylene is to be recovered from the product slate, the IRR of the HS-FCC option reached 24 to 28% depending on the severity of operation, in spite of the larger investment needed to expand capacities of para-xylene, propylene, MTBE and alkylation units. Table 1. HS-FCC Pilot Plant Results at 600 C, Catalyst/Oil Ratio of 40 and 84 wt% Conversion Product Yields wt% Base Catalyst Base +10wt% ZSM-5 Ethylene 1.8 3.1 Propylene 10.7 18.4 Butylene 16.1 17.8 28.7 39.3 Total Light Olefins Dry Gas 4.6 5.5 Gasoline 45.4 34.0 Light Cycle Oil 9.4 9.3 Heavy Cycle Oil 6.6 7.1 Coke 3.1 3.5 Table 2. Incremental Investment and IRR for base and HS-FCC Refineries HS-FCC Upgraded Refinery Parameter Base Case-1 Case-2 Refinery Propylene Recovery Option Incremental Investment MM$ Base +106 +144 Incremental Return, MM$ Base +26 +37 IRR, % -17.2 17.9 Para-xylene Recovery Option Incremental Investment MM$ +200 +332 +441 Incremental Return, MM$ +58 +120 +186 IRR, % (Para-xylene recovery) 20.1 24.3 27.7 Based on the success of pilot plant testing, a 30 bbl/d HS-FCC demonstration plant is being designed and will be constructed at a local refinery in Saudi Arabia. Catalytic cracking of VGO under high severity in a downer-type reactor boosts overall conversion and enhances the production of gasoline and light olefins. The addition of ZSM-5 is effective in catalytic systems where the base catalyst have low
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hydrogen transfer activity. The results of economic evaluation showed that propylene and para-xylene production plays a major role in the economics of the upgraded refinery with HS-FCC option. 3.4 HS-FCC Demonstration Plant Currently a 30 bbl/day HS-FCC demonstration plant is being designed. The plant will be constructed and operated near a Saudi Refinery in the second quarter of 2002. The demonstration plant comprises three sections for reaction, regeneration and stripping. The reactor section consists of two devices: the feed nozzle of which there are five feed nozzles, one located at the center of the reactor and the other four feed nozzles are distributed equally at the sides of the reactor to achieve good mixing between the catalyst and feed. The gas product that leaves the reactor at a high temperature of around 600C is quenched by light cycle oil (LCO) at about 500C to help prevent over cracking that results in dry gas formation.

Cited References 1. Fujiyama, Y., 1999, Process for Fluid Catalytic Cracking of Oils, US Patent No. 5,904,837. 2. Maadhah, A., Abdul-Hamayel, M., Aitani, A., Ino, T. and Okuhara, T., 2000, Down-flowing FCC Reactor Increases Propylene and Gasoline Make, Oil and Gas Journal, 98 (33), pp. 66-70. 3. Okuhara, T., Ino, T., Abul-Hamayel, M., Maghrabi, A., and Aitani, A., 2001, Effect of ZSM-5 Addition on Product Distribution in a High Severity FCC Mode, Petroleum Science and Technology, 19, p. 685.