Different process schemes for converting light straight run and fluid catalytic cracking naphthas in a FCC unit for maximum propylene production

Abstract

Light straight run (LSR) and fluid catalytic cracking (FCCN) naphthas were cracked in a transported bed reactor (MicroDowner) and in a fixed bed reactor (MAT) over a commercial Y zeolite based catalyst, over a commercial ZSM-5 zeolite based additive, and over a mixture of both at selected conditions. Based on the mechanisms through which naphtha hydrocarbons are converted, we evaluated the best alternatives for processing these streams to produce light olefins and/or to reduce olefins content in commercial gasoline. The experimental set-up allowed us to simulate the cracking behaviour of the different naphtha streams in a fluid catalytic cracking (FCC) unit by different processing schemes. Results indicate that LSR only cracks at high severity, yielding large amounts of dry gas. Despite its high olefins content, FCCN practically does not crack when it is fed together with gas oil feed. When cracking FCCN alone at typical gas oil cracking conditions, olefins are transformed preferentially into naphtha-range isoparaffins and aromatics, and when cracking FCCN at high severity, olefins are transformed preferentially into propylene and butylenes. Finally, cracking naphtha in the stripper produces some propylene and increases the aromatics in the remaining gasoline.