process heavier, more contaminated feeds under such conditions, while lowering feed cost, demands robust management strategies. Ketjen’s advanced FCC catalyst formulations are designed to maintain activity and selectivity under severe conditions, while its contaminant mitigation technologies help refiners manage metals such as iron, vanadium, nickel, and sodium. These solutions enable refiners to catalyst systems and contaminant
Ethylene (C =)
Propane dehydrogenation (PDH)
Ethane, propane butane, NGLs (C +)
Propylene (C =)
LPG
Steam cracking
Butadiene (C==)
LN
Pygas
Crude oil
Reformate
Catalytic reforming (CR)
Aromatics complex
HN
BTX
C =, C =
Fluidised catalytic cracking (FCC)
Re nery operations
Methanol to ole ns (MTO, MTP)
Gasi cation & methanol synthesis
Methanol
Coal
SMR & methanol synthesis
Natural gas
Figure 1 Conventional max propylene and high-severity FCC unit for process intensification in an integrated refinery/petrochemical complex
Unlocking petrochemical potential through high-severity cracking To meet the rising demand for petrochemicals, Indian refiners are turning to high-severity FCC technologies such as PMcc (Technip Energies), and Indmax (Lummus). Including HS-FCC (Axens/Technip), these units operate at higher reactor outlet temperatures, shorter contact times, and elevated catalyst-to-oil ratios, enabling significantly higher yields of propylene, butylene, and even ethylene. A critical enabler of these performance gains is the use of highly selective zeolites, such as ZSM- 5. ZSM-5’s unique shape-selective properties promote the cracking of gasoline-range olefins into light olefins, particularly propylene, making it indispensable for pushing the established boundaries of propylene yield in high-severity operations. However, these gains come with challenges. High-severity operation increases dry gas production, requiring tighter integration with downstream gas recovery and olefins separation systems. Moreover, the ability to “ To meet the rising demand for petrochemicals, Indian refiners are turning to high-severity FCC technologies ”
maximise petrochemical yields, maintain unit reliability, and adapt to fluctuating feedstock quality, all while supporting integration with downstream product recovery systems. Catalyst innovation as a bridge between fuels and petrochemicals The convergence of refining and petrochemicals requires a new generation of catalysts that can deliver high light olefin yields while managing complex feeds. Ketjen’s innovations in low hydrogen transfer zeolites, high matrix activity, and advanced assembly techniques are enabling refiners to push the boundaries of propylene production, even in high-iron environments. Case study: increased propylene from heavier residues Taiyo Oil Company’s Shikoku refinery in Japan operates an advanced FCC unit designed by UOP and equipped with RxCat technology. The company’s strategic objective is to maximise profitability and operational flexibility by processing 100% untreated residue feed. This is a challenging goal due to significant fluctuations in feed quality, particularly in Conradson carbon residue and contaminant metals such as iron. Taiyo Oil’s FCC unit is tasked with producing high- quality fuels and petrochemicals, with a special focus on propylene, a key building block for the rapidly expanding petrochemical sector in Asia.
Refining India
6
Powered by FlippingBook