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Catalytic cracking is a vital process in petroleum refining that converts heavy oils into lighter, high-value products, primarily gasoline, using catalysts like zeolites. The process involves pretreatment of feedstocks, follows specific chemical reactions, and operates in a fluidized-bed system with key zones including the regenerator and reactor. Environmental considerations and economic factors, such as catalyst costs and energy recovery, are crucial for optimizing the process and addressing industry trends.

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13 views12 pages

Wa0011.

Catalytic cracking is a vital process in petroleum refining that converts heavy oils into lighter, high-value products, primarily gasoline, using catalysts like zeolites. The process involves pretreatment of feedstocks, follows specific chemical reactions, and operates in a fluidized-bed system with key zones including the regenerator and reactor. Environmental considerations and economic factors, such as catalyst costs and energy recovery, are crucial for optimizing the process and addressing industry trends.

Uploaded by

ahmedalee4537
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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CATALYTIC CRACKING IN PETROLEUM REFINING

CHEMICAL ENGINEERING DEPARTMENT


LECTURE PRESENTATION
INTRODUCTION TO CATALYTIC CRACKING

 Converts heavy oils to lighter, high-value


products
 Preferred over thermal cracking for
higher gasoline yield
 Crucial in modern refinery operations
(~10.6 MMBPD processed)
FEEDSTOCKS AND PRETREATMENT

 Common feeds:Vacuum gas oil,


atmospheric gas oil
 Pretreatment removes sulfur, metals, and
nitrogen
 Hydrotreating improves conversion and
yield
CRACKING CHEMISTRY AND REACTIONS

 Follows carbonium ion mechanism


 Primary: C–C bond scission, hydrogen
transfer
 Secondary: Isomerization,
polymerization, aromatization
CATALYSTS USED IN FCC

 Amorphous silica-alumina
and zeolites
 Zeolites: Higher activity and
selectivity
 Deactivation by coke and
metal contamination
FCC PROCESS AND
REACTOR DESIGN

 Fluidized-bed or riser-type
systems
 Regenerator burns coke,
provides heat
 Side-by-side and stacked
reactor configurations
 FCC is divided into three key zones: Regenerator, Reactor, and
Fractionation Tower
 Spent catalyst from the reactor is regenerated by burning coke
deposits in the regenerator
 Hot regenerated catalyst mixes with pre-heated feed oil in the
reactor riser
 Cracking reactions occur as oil vapor contacts the hot catalyst
 Vaporized products flow to the fractionation tower for separation
into gasoline, gas oil, and other fractions
 Catalyst particles are continuously circulated between the
reactor and regenerator
Temperature: 900–1000°F (reactor),
1200–1500°F (regenerator)

KEY OPERATING C/O ratio: 5–16, space velocity: 1.1–13.4


PARAMETERS

Conversion affected by time, temp,


catalyst activity
Main products: Gasoline, LPG,
LCO, coke, gases

FCC PRODUCT Zeolite catalysts yield more


YIELDS gasoline and less coke

Conversion levels typically 65–


85%
Coke burn-off generates flue gases (CO,
CO₂, NOx)

ENVIRONMENTAL
SOx from sulfur, mitigated by sulfur-
AND ENERGY transfer catalysts
ASPECTS

Heat recovery: CO boilers, steam and


power generation
Capex varies with capacity and
complexity

ECONOMICS
Opex includes catalyst, utilities, labor,
AND COST royalty
FACTORS

Catalyst cost: $900–$3000/ton; power-


intensive
Resid cracking and metals tolerance
gaining focus

CONCLUSION
Higher propylene production via
AND INDUSTRY catalyst design
TRENDS

Ongoing innovation: zeolite tuning, unit


revamps

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