Revamping Fluid Catalytic Cracking Unit, and Optimizing Catalyst to Process Heavier Feeds

Abstract

H-Oil gas oils have a higher density and higher nitrogen content, and consequently much lower reactivity than straight-run vacuum gas oils during fluid catalytic cracking (FCC). The conversion of H-Oil gas oils observed in a laboratory catalytic cracking unit at constant operating conditions showed a 20 wt.% lower conversion rate than straight-run hydrotreated vacuum gas oil. Thus, a revamp of commercial FCC units, and the selection of a higher activity catalyst with lower coke selectivity is needed to provide the stable trouble-free operation of the unit. The performed revamp of the commercial FCC unit allowed a stable operation at a higher throughput. It also allowed an increased riser outlet temperature from 532 to 550 °C; increased maximum allowable regenerator temperature from 705 to 730 °C; decreased afterburning from 12 to 6 °C; decreased NOx emissions in the flue gas from 250 to 160 mg/Nm3; improved catalyst regeneration; decreased catalyst losses to 0.0142 kg/t feed; and improved catalyst circulation at a higher throughput. It was confirmed in the commercial FCC unit that the H-Oil light vacuum gas oil is the least reactive H-Oil gas oil during catalytic cracking.