FCC catalyst feed and PPO properties
FCC catalyst feed and PPO properties
S. No Parameters
PPO 0.79
FCC catalyst feed
Parameters
Value
1 2 3 4 5 6 7
Density, g/cc
0.938
MAT, wt%
69
Conradson carbon residue, wt%
0.1 58 2.8 11 50 70
1.7
Nickel, ppmw
3,746 2,283
Bromine number
2 0
Vanadium, ppmw
Diene
Total surface area, m²/g Apparent bulk density, g/cc
121 0.83 0.57 3.45
Sulphur, ppm Chloride, ppm
23,352
1.1
P 2 O 5 , wt% RE 2 O 3 , wt%
Total nitrogen, ppm
752
Table 1
Table 2
One major concern is the presence of oxygenates and olefinic components in PPO, which may lead to excessive coke formation during processing in the FCC unit. High coke yield can reduce catalyst efficiency and necessitate frequent regeneration cycles, “ Advances in catalyst technology, feedstock treatment, and process optimisation will play a crucial role in enabling the successful integration of plastic waste-derived feedstocks into existing refining infrastructure ” increasing operational costs. Additionally, contaminants such as chlorine, nitrogen, and sulphur can cause corrosion in the main fractionator and gas concentration section of the FCC unit, leading to maintenance issues and possible equipment degradation. High
chloride and nitrogen content of PPO causes ammonium chloride corrosion in the top trays of the main fractionator, whereas high sulphur content causes ammonium sulphide corrosion in the main fractionator overhead condenser. Ammonium chloride salt deposition can be avoided by operating the main fractionator column top temperature above the ammonium chloride sublimation temperature, whereas ammonium sulphide corrosion can be reduced in the overhead section by using wash water and corrosion inhibitors. The composition of PPO also tends to vary, depending on the source and type of plastic waste used in pyrolysis, making process optimisation challenging. Ultimately, while FCC is a highly efficient process for converting VGO into valuable products, adapting it for alternative feedstocks like PPO requires overcoming technical and operational challenges. Advances in catalyst technology, feedstock treatment, and process
optimisation will play a crucial role in enabling the successful integration of plastic waste-derived feedstocks into existing refining infrastructure. Co-processing of PPO in FCC unit Co-processing of plastic pyrolysis included the selection of oil suitable for HPCL FCC units, studying the impact of PPO on FCC product yields, tuning FCC
80
100% FCC feed 0.5% PPO + 99.5% FCC cat feed 5% PPO + 95% FCC cat feed
70
60
50
40
30
20
10
0
Dry gas
LPG
CRN
LCO
Resid
Coke
Conversion
Figure 2 Product yields obtained in laboratory catalytic cracking for 0.5% and 5% PPO processing
Refining India
12
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