Abstract
A new approach for characterization of fluid catalytic cracking (FCC) catalysts is proposed. This approach is based on computational visual analyses of images originating from field emission scanning electron microscopy (FE-SEM) studies coupled with elemental mapping via electron dispersive x-ray spectroscopy (EDX) analyses. The concept of contaminant metal mobility is defined and systematically studied through quantification of interparticle transfer and intraparticle penetration of the most common FCC contaminant metals (nickel, vanadium, iron, and calcium). This novel methodology was employed for practical quantification of intraparticle mobility via the Peripheral Deposition Index (PDI). For analyzing and quantifying interparticle mobility, a new index was developed and coined “Interparticle Mobility Index” or IMI. With the development and practical application of these two indices, this study offers the first standardized methodology for quantification of metals mobility in FCC. This novel systematic approach for analyzing metals mobility allows for improved troubleshooting of refinery-specific case studies and for more effective research and development in contaminant metals passivation in FCC catalysts.
Highlights
This novel systematic approach for analyzing metals mobility allows for improved troubleshooting of refinery-specific case studies and for more effective research and development in contaminant metals passivation in fluid catalytic cracking (FCC) catalysts
We previously reported the use of scanning electron microscopy (SEM) imaging to quantify intraparticle metal mobility on FCC equilibrium catalysts (Ecats) and laboratory deactivated catalysts (Dcats) [15]
An Ecat sample from a North American refinery was examined via field emission scanning electron microscopy (FE-SEM)
Summary
Fluid catalytic cracking (FCC) is a refining process that converts crude oil derived feeds (often pre-processed by distillation and/or hydrotreating units) into valuable products including liquified petroleum gases (LPG), gasoline, and diesel precursors. FCC is often the major conversion unit in the refinery and is touted for its flexibility, since it can process feeds from various crude oil sources and of various qualities. The FCC is responsible for the production of most of the world’s gasoline and is thought of as fueling the world’s transportation networks. The FCC catalyst is prone to deactivation, and unwanted side reactions due to contaminant metals, including nickel (Ni), vanadium (V) and iron (Fe), coming into the unit with residue containing feedstocks (i.e., resid feeds)
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