Chapter 1 Origin, Development and Scope of Fcc Catalysis

Abstract

This chapter discusses the origin, development, and scope of Fluid Catalytic Cracking (FCC) catalysis. The cracking catalyst is only one of the many components in a modern FCC catalyst system. Other main ingredients catalyze reactions such as carbon monoxide and sulfur dioxide oxidation in the regenerator, contaminant metals passivation, and further cracking and isomerization over a smaller pore zeolite. The place and role of the FCC unit (FCCU) in the petroleum refinery has evolved over the past fifty years. Originally, in the 1940s, the catalytic cracking unit, a Houdry fixed-bed, a moving-bed Thermofor Catalytic Cracking (TCC), or one of the early FCC designs was meant to complement the thermal cracker. Feed was mostly vaporized light gas oil. When mixed with alkylate and tetraethyl lead, light FCC naphtha could produce aviation gasoline of 100 research octane. After the war, demand for octane slackened, and the units were operated at lower severity for some time. By the 1970s, FCCs replaced fixed- and moving-bed crackers. The introduction of zeolites (first commercialized in TCC) has had a major effect on FCC design. The dense-bed reactor was replaced by a short-contact-time riser. Platinum reforming was now well established, and some refineries began hydrocracking light cycle oil to increase gasoline production. Environmental regulations, lead-phaseout, and oil supply shocks had a profound effect on the refining industry and on FCCs.