MAXIMIZE OLEFINS THROUGH CATALYTIC CRACKING

INDMAX FCC (I-FCCSM) PROCESS

Dalip Soni, Philip J Angevine, Rama Rao
Lummus Technology Inc., Bloomfield, NJ, USA
G Saidulu, D Bhattacharyya, V Krishnan
Indian Oil Corporation Ltd, R&D Centre, Faridabad, India

Overview
The primary purpose of the fluid catalytic cracking (FCC) process historically has been to
convert low-valued, heavier petroleum streams into gasoline, alkylation feed (e.g., isobutane
and butene) and, to a lesser extent, other distillate products. While other light olefins were
always produced, the low volumes did not attract much attention because of the separation
costs and modest margins.
Production of propylene from FCC units has grown significantly in the last decade and is
now approaching 20-30% of the total propylene produced worldwide1. The price spread
between propylene and gasoline and increase in demand for propylene have been the key
drivers. Significant improvements have been made in the FCC catalyst formulation and process
technology to maximize propylene yield from the FCC units. This relatively new strategy for
on purpose production of FCC propylene will help meet approximately 5% of the annual
growth rate in worldwide propylene demand1.
Early attempts to increase light olefins from FCC were based primarily on process variables,
but poor selectivity of this approach resulted in excess dry gas and coke make. By the 1970s,
researchers found that non-Y zeolites could also co-produce light olefins (C2= to C5=), often at
the expense of gasoline. Table 1 below shows the chronology of catalyst and additive
developments for light olefins enhancement in FCC units.
Table 1. Timeline of Zeolites use for Higher FCC Olefins Production
Year
1970
1974
1983
1986
1990

Event
ZSM-5 in FCC invented
USY use in FCC invented
ZSM-5 commercialized in cracking
Zeolite Beta in FCC invented
First on-purpose olefins production
via ZSM-5
1995 IndmaxSM FCC process invented
2003 Indmax process commercialized

This paper discusses the growth of on purpose light olefins production as an FCC
objective and the approaches employed. Specifically, the IndmaxSM FCC (I-FCCSM) process will
be addressed, including its benefits, the underlying concepts, the chronology of its
development, and its commercialization.

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Approaches to Higher Olefins Production

Process Variables
Some of the FCC process variables employed for olefin production include: (a) higher
severity operation, (b) re-cracking of the cracked material, and (c) partial catalyst recycle.
Table 2 summarizes the benefits and drawback of such variables.
Table 2. Benefits and Drawbacks of Process Options
Process
High severity operation
Short contact time
Long contact time
Re-cracking of cracked
material (naphtha)
Partial catalyst recycle

Pros
Low-cost route to
increased olefins

Cons
Excess dry gas/coke make

Product selectivity
optimization
Increased catalystto-oil ratio

Excess dry gas at the

expense of gasoline product
Poor selectivity

High severity operation is achieved by high reaction temperature with or without higher
residence time. The general concept for higher severity operation is to overcrack (beyond
maximum gasoline mode) and produce increased quantities of light olefins. The major
drawback of this approach is the production of excess dry gas and subsequent overloading of
the gas plant (compressor and separator). Also, higher severity results in higher coke make2
and higher diene content in gasoline that can lead to gum formation. This whole approach is
somewhat of a brute force method with little control over the desired products.
Re-cracking of cracked material like naphtha can yield incremental light olefins. This recracking can be done in the same or a separate riser/reactor. The concept of injecting in the
same riser/reactor has been used for upgrading visbreaker or coker naphtha in FCC risers.
Recycle of FCC naphtha to the same riser reactor has also been implemented; however, dry
gas yield increases significantly.
In the partial-catalyst-recycle approach, part of the spent catalyst is recycled back to the
reaction section to increase the catalyst-to-oil ratio. The drawback is that the average catalyst
activity is low compared to the case when higher catalyst-to-oil ratio is achieved with all
regenerated catalyst. Therefore the partial-catalyst-recycle approach results in lower
conversion and selectivity to light olefins.

Catalyst Variables
Since the 1960s, the refining industry has used various X and Y zeolites as its primary
cracking catalyst in FCC3, 4 . Stability and selectivity benefits quickly led to the use of Zeolite Y
exclusively. The phase-out of lead caused researchers to seek alternate routes to increased
gasoline octane. Several versions of Y zeolites were used, and these are listed in Table 3.

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Table 3. Benefits and Drawbacks of Catalyst Options

Catalyst
Ultrastable Y (USY)
RE-USY
ZSM-5

Pros
More C3=/C4=; less coke
Improved stability versus
USY
Excellent C3= yields

Zeolite Beta

Enhanced C4=

Cons
Poor stability
Limited olefin potential
Poor conversion activity;
additive dilution effect
High cost; poor stability

Delta wt% of C4-C5 Olefins

Many methods were tried to dealuminate zeolite Y to balance activity, stability, gasoline
yield, and octane. The use of zeolite Y for increased olefins focused on ultrastable Y, achieved
mainly by its decreased zeolite unit cell size and decreased framework Al content.5, 6 At
constant conversion, USY catalysts yield more C3-C4 olefins, higher-octane gasoline, and less
gasoline and coke. One patent7 showed that olefins yield reached a maximum at unit cell size
a0 of 24.15-24.20 . Figure 1 shows olefin yield as a function of unit cell size. Unfortunately,
USY is less active and stable than its REY counterpart. RE-USY can achieve benefits similar to
USY, but with about 35% higher activity than USY.8
4
3

2
1
0
24.36

24.33

24.25

24.19

Unit Cell Size (

)

24.18

24.15

24.02
C4

C5

Figure 1. Incremental olefin yields for various USY catalysts

Currently, the popular approach to olefin production is the use of ZSM-5 additive.9 ZSM-5
was first explored as a stand-alone FCC catalyst, but found to be lacking in conversion activity
not surprising for a medium-pore-size zeolite. It was later proved that ZSM-5 enhances
gasoline octane when used as an additive to the main FCC catalyst, due to the ability of ZSM-5
to produce more olefins.
While early ZSM-5 use focused on octane enhancement, the use of larger quantities of
ZSM-5 for on purpose propylene production started in the 1990s. Refiners have since
increased their reliance upon ZSM-5 to the point where it now is used in almost 20% of
worldwide FCC capacity. This approach has proven to be a relatively inexpensive route to
propylene.
ZSM-5 can be used as a separate additive or as an integral part of the FCC catalyst. Each
approach has its benefits and drawbacks. Since the two zeolites (Y and ZSM-5) age at
different rates, the separate additive method can adjust better for this effect. However, the

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additive can build up in the FCC inventory to the point where this dilution can reduce the
overall conversion performance of the catalyst mix. Using the integral, single particle
approach, the Y zeolites has to have some extra activity so-called activity giveaway
which may not be easily achieved. This approach also does not allow the flexibility to change
the percentage of ZSM-5 in the total catalyst inventory in the event of feedstock changes or
fluctuations in market product demand.
The generally accepted mechanism for ZSM-5s utility is the secondary conversion of
heavier gasoline olefins to lighter (e.g., C3 and C4) olefins as well as isobutane.10, 11, 12 The
gasoline paraffins have been shown to be a hundred-fold less reactive than the olefins.13
Feedstock plays a key role in the abundance of gasoline olefins. For example, highly paraffinic
crudes (e.g., Minas, etc.) are the most responsive to ZSM-5, while aromatic crudes (e.g., San
Joaquin) are significantly less effective for octane boost and olefin production.

The I-FCC, I-RFCC Process

The Indmax process, developed by the Indian Oil Corporation (IOCL), is a breakthrough in
FCC technology for converting heavy feeds, including residue, to light olefins14. This process
overcomes the drawbacks or limitations of just adding ZSM-5.
The Indmax process employs a riser reactor system along with a catalyst stripper and
catalyst regenerator, just like a conventional FCC unit. The process uses a multi-component,
multi-functional, proprietary catalyst formulation that is very selective in cracking molecules of
different shapes and sizes to yield very high quantities of light olefins. At the optimum
formulation, different components work synergistically to provide high catalyst activity, and
hence conversion, along with high selectively to light olefins. Figure 2 clearly reflects these
attributes of high coke and dry gas selectivity, as the Indmax process produces much less
coke and dry gas (at constant conversion) when compared with resid FCC catalyst.

Figure 2. Indmax catalyst performance versus conventional FCC/RFCC route with respect
to coke and dry gas selectivity

The Indmax catalyst formulation is unique and very different from what has been used in
FCC or RFCC operations. The multi-component catalyst approach provides flexibility to change
the catalyst formulation quickly and meet the challenges of fluctuations in feedstock properties
or product demand. The catalyst formulation is specific to each operation and depends on the
feedstock characteristics and product objectives. Extensive research studies have been
conducted for various feedstocks to determine the light olefins yields and selectivity. Table 4

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summarizes the range of olefins yield and selectivities that can be obtained from different
feedstocks and operations.
Table 4. Typical Olefin Yields for the I-FCC Process

Ethylene
Propylene
i-Butylene
Other
butylene

Wt% of
feed
3-7
12-24
4-5

Wt% in
DG/LPG
40-50
40-50
8-12

5-12

20-25

The Indmax catalyst formulation is also highly tolerant of metals and can operate with
high vanadium concentration on the equilibrium catalyst. This ability to accept feeds with high
metals level is very important for residue operations.
The Indmax process utilizes higher riser reactor temperature (560-600C), higher
catalyst-to-oil ratio (12-20), and lower hydrocarbon partial pressure to achieve high conversion
and selectivity for light olefins production. Since all the cracking reactions take place in the
short-contact-time riser reactor, and with very high catalyst-to-oil ratio and all high activity
regenerated catalyst, the selectivity to light olefins is very high. The LPG produced contains up
to 50 wt% propylene and 12 wt%
isobutylene. Total olefins in LPG can be as
high as 80 wt%. The Indmax process can
accept
feedstocks
ranging
from
hydrotreated vacuum gas oil to residue.
The first commercial unit (Figure 3) to
utilize
the
Indmax
process
was
commissioned in 2003 at the Guwahati
Refinery (Assam, India). With a capacity of
100,000 metric tons per annum, it has been
running smoothly since startup, producing
products with the desired specifications.
The plant performance test run data is
presented in Table 5. The unit operates on
a heavy feed with CCR of 3.75 wt%. The
Figure 3. 100,000 Indmax Unit, Guwahati, India
regenerator
operates
in
complete
combustion without a catalyst cooler and
coke of regenerated catalyst (CRC) is less than 0.05 wt%. The unit achieves very high
conversion with propylene yield of about 17.2 wt% of total feed. Excellent coke selectivity of
the catalyst makes it possible for this unit to be run in complete combustion without a catalyst
cooler.

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The I-FCC unit is designed by Lummus Technology, a CB&I company (Lummus) with basic
process information developed by IOCL. Lummus is a Licensor of state-of-the-art FCC and
RFCC technologies, while the IOCL R&D Center is a premium research and development
organization in the field of catalyst and process
Table 5: Indmax Commercial plant
development. This combination provides an inperformance data
depth and extensive knowledge base that is
Parameter
Indmax
used in the design of each I-FCC unit.
Feed
The reactor regenerator section equipment
Mix of Atm. Residue,
and hardware pieces are designed to utilize
Feed Composition
Delayed Coker Liquid the maximum potential of the Indmax catalyst
Products
and the given feedstock to produce light
Feed Density
olefins. The key process features include:
0.9456
(ATB+CHGO)
Micro-Jet Feed Injectors: These
0.7164
Coker Naphtha
injectors maximize selective catalytic cracking
reactions by thoroughly contacting the feed
CCR (ATB+CHGO)
3.75 wt%
with the hot regenerated catalyst and rapidly
Yield, wt%(fresh feed basis)
vaporizing it. In the Micro-Jet injector design,
Dry gas/ethylene
7.4/3.3
the inherent energy of the feed dispersion
LPG/Propylene
36.3/17.2
steam is used to shear the feed into small
Gasoline (C5-200oC)
34.7
droplets. Figure 4 is a schematic of the MicroConversion, wt%
Jet
injector. It consists of a double pipe
86
( up to 200 C D86)
wherein the oil flows through the center pipe
Gasoline Octane
and steam flows through the annulus. The
99
(RON)
cylindrical flow of oil is turned into thin films as
it flows past a device attached at the end of the center pipe. The thin films of oil are then hit
by several jets of dispersion steam, which is flowing in the annulus. The small droplets formed
are then quickly ejected into the riser through a specially designed tip that generates several
micro jets designed for the optimum exit velocity when entering the riser.

Steam

Oil Feed

Figure 4 Schematic of Micro-JetTM Injectors

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Each individual jet is angled such that all the jets collectively form a flat fan spray pattern
for maximum coverage of the riser cross section. This design ensures uniform distribution of
feed across the riser while preventing riser erosion and catalyst attrition. The angle of injection
is optimized to achieve thorough contact of oil and catalyst. The injection velocity is optimized
so that it is high enough to penetrate the catalyst mass yet does not cause catalyst attrition and
riser erosion.
Riser Design: The riser residence time and velocity are optimized to maximize catalytic
cracking reactions, minimize undesirable thermal cracking reactions, and maximize selectivity
to olefins. Riser residence time is optimized through pilot plant tests and kinetic model studies.
The riser diameter, and hence velocity, is optimized by tracking the volume expansion as the
reaction mixture flows up the riser by means of a computer model. The riser design
approaches plug flow conditions with minimum slip, which enhances catalytic cracking
reactions and hence selectivity to light olefins.
Reaction Termination Device (RTD): Direct-coupled cyclones
Figure 5
are used at the end of the riser reactor to quickly and efficiently recover
To Fractionator
product vapors at the end of the riser and terminate the reactions
Vents
(Figure 5). Due to the strong cyclonic forces, most of the catalyst is
P
thrown against the cyclone wall immediately after exiting the riser
P
reactor and separates from the product vapors. There is essentially no
P
time for the bimolecular, post-riser, hydrogen-transfer reactions that resaturate the olefins made in the riser, to take place.
Another unique feature of Lummus Technologys RTD design is
Stripper
Gas
that the primary/riser cyclone operates at a pressure lower than that in
the cyclone containment vessel or reactor. As a result, the recovery of
products at the end of the riser is almost complete and post-riser
P >P
residence time is minimal. This further helps in preserving olefins
produced in the riser reactor by selective catalytic cracking . In addition, entrainment of the
product vapors with the spent catalyst is minimal. This reduces delta coke and hence
regenerator temperature which in turn helps to increase catalyst-to-oil ratio that is critical for
achieving high yield of light olefins. In summary, this RTD design preserves and promotes the
selective component cracking characteristic of the I-FCC reaction system.
Modular Grid (MG) Catalyst Stripper: This stripper design uses flat baffles that are
angled and oriented such that the entire cross-sectional area of the stripper is available for
catalyst flow and maximum surface area is available for catalyst and stripping steam contact
(Figure 6). The baffles are assembled and built as modular grids that can be installed in the
stripper vessel by simply stacking them over one another. These grids can be easily inspected
in place through manholes provided in between the stacks.
3

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Figure 6 Highly efficient modular grid stripper internals

The MG Stripper is highly efficient compared to other designs. It can accept very high
catalyst flux rates and still maintain excellent efficiency. Advantages of the MG Stripper
include reduced dry gas, reduced delta coke (and hence higher catalyst-to-oil ratio), increased
conversion/yield of light products, and higher selectivity to light olefins.
Lummus Technologys FCC reactor-regenerator design is complimented by a very stable
catalyst circulation system and an efficient catalyst regenerator design, including highly
effective spent catalyst and air distributors. All these design features are successfully operating
in several FCC units worldwide. Performance of FCC units improved significantly after these
were revamped by incorporating some or all of the hardware design features described
above.
When the objective is to produce light olefins from heavier feedstocks having high CCR and
metals, major concerns are excessive coke make, high regenerator temperature, high dry gas
make, and high catalyst makeup rates. The low delta coke and dry gas selectivity, and high
metals tolerance of the Indmax catalyst, in conjunction with the hardware design
improvements, allow I-FCC and I-RFCC to easily handle these difficult feedstocks. It is worth
noting that I-RFCC can process heavy feedstocks with CCR as high as 5.0 wt% without a
catalyst-cooler.
Lummus Technology and the IOCL R&D Center have recently completed the design of an
85,000 BPSD I-FCC unit with the objective of maximizing propylene and ethylene from
hydrotreated VGO feed. The unit, scheduled for startup in 2010, will maximize propylene yield
and also produce an increased quantity of ethylene as feed to the downstream petrochemical
complex. The I-FCC process has the flexibility to either maximize production of propylene plus
ethylene, or maximize propylene alone, without an increase in ethylene yield. The design of
another 15,000 BPSD unit with heavier feed is in progress, with the objective to maximize
LPG/propylene plus gasoline. The design of these two units demonstrates the full flexibility of
the I-FCC process with regard to product slate optimization and /or processing a wide range
of feedstocks.

Conclusion
The I-FCC/I-RFCC process is a very significant advance in the field of light olefins
production by catalytic cracking. This process can upgrade heavy feeds (including residue)

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with high yield of light olefins such as propylene, ethylene, and butylenes. This is due to the
combination of unique catalyst formulation, hardware design, and operating strategy.
The I-FCC/I-RFCC process is highly flexible as it involves only riser cracking. The operation
can be easily adjusted depending on the demand and pricing of different products. The multicomponent catalyst approach offers further flexibility by easily adjusting the catalyst
formulation to meet any changes in feedstock properties or market demand of the various
products. I-RFCC offers technological advantages in terms of low delta coke, and dry gas
production. These factors assume added importance when processing heavier feedstocks. The
need for a catalyst cooler in many situations is eliminated.
References
1.
2.

CMAI News, Nov.12, 2001.

Hutchinson, D.; Hood, R.; Catalytic Cracking to Maximize Light Olefins, PETROLE ET
TECHNIQUES, March April 1996, 29.
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4.
U.S. 3,140,251 (to Socony Mobil) July 7, 1964.
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U.S. 3,595,611 (to WR Grace) July 27, 1971;
6.
U.S. 3,957,623 (to WR Grace) May 18, 1976.
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U.S. 5,549,813 (to Texaco) August 27, 1996
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Buchanan, J. Scott; Adewuyi, Applied Catalysis A: General 134 (1996) 247-262.
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U.S. 3,758,403 (to Mobil) September 11, 1973.
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Rajagopalan, K.; Young, G.W.; Am. Chem. Soc. Symp. Ser., 375 (1988) 34.
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Madon, R.J.; J. Catal. 129 (1991) 275.
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Buchanan, J.S.; Appl. Catal. 74 (1991) 83.
13.
Haag, W.O.; Lago, R.M.; Weisz, P.B.; Discuss. Faraday Soc. 72, 317 (1981).
14.
Upadhyay et al; Successful Demonstration of Indmax Process for Conversion of
Residues to LPG and High Octane Gasoline, International conference Petrotech-2005 held at
New Delhi in January 2005.

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