pt q&a
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Q What are the optimal pathways towards increas- ing naphtha and LPG production (for petrochemical feedstocks)? A Mark Schmalfeld, Global Marketing Manager, mark. schmalfeld@basf.com, Hernando Salgado, Technical Service Manager IMEA, hernando.salgado@basf.com, and Alvin Chen, Global Technology Application Manager, alvin.u.chen@basf.com , BASF Refinery Catalysts Production of naphtha and liquefied petroleum gas (LPG) as petrochemical feedstocks is critical for meeting the demands of various industries. To increase the yield of these valuable products, a multifaceted approach is essen - tial, focusing on optimising processes, catalysts, and opera - tional parameters. Several optimal pathways can enhance the production of naphtha and LPG via fluid catalytic crack - ing (FCC), hydrocracking, and catalytic reforming. FCC is a widely utilised process for converting heavy hydrocarbons into lighter products. The selection of advanced zeolite-based catalysts is pivotal because they can significantly enhance selectivity towards naphtha and LPG. Innovations in catalyst composition, including the incorporation of specific metals or alterations to the pore structure, can lead to improved performance and greater product yields. Additionally, optimising reaction conditions such as temperature and pressure is crucial for maximising the production of lighter hydrocarbons. Higher temperatures generally favour LPG yield, while specific pressure adjustments can enhance naphtha pro - duction. High-severity FCC operation can further maximise light products (LPG, C2=) if the refinery has appropriate product recovery facilities. However, the high coke yield and high cat-to-oil required to achieve high-severity opera - tion may require significant feed rate reduction. Hardware design features, such as a dedicated riser to catalytically crack recycled naphtha to more light olefins or special riser terminations to increase residence time, are an additional handle to maximise light olefins production. Hydrocracking is another critical process that can be optimised to improve yields. The development of bifunc - tional catalysts that combine hydrogenation and crack - ing functionalities can enhance the conversion of heavier feedstocks into lighter products, such as naphtha and LPG. Furthermore, maintaining an adequate supply of hydrogen is essential for facilitating hydrocracking, which can further increase LPG yields from heavier fractions. Catalytic reforming processes also play a vital role in converting naphtha into high-octane gasoline components and generating aromatics. By adjusting catalyst properties and operating conditions, the catalytic reforming process can be optimised to maximise LPG yields as a byproduct while simultaneously improving the quality of gasoline components. Integrating reforming with other processes can recycle hydrogen and maximise the overall efficiency of
naphtha conversion, creating a more streamlined produc - tion chain. Utilising diverse feedstocks is also essential for enhancing naphtha and LPG yields. Employing a variety of feedstocks, including heavier crude fractions and biogenic sources, can lead to increased overall production. Tailoring processing conditions based on the characteristics of the feedstock can further optimise yields. Additionally, implementing pretreat - ment processes to remove impurities can enhance the qual - ity of the feedstock before it enters conversion units, thus improving the efficiency of subsequent processing steps. Effective heat and energy management strategies are a key consideration for lowering operational costs to make the economics of naphtha and LPG production more attrac - tive. Implementing heat integration and recovery systems minimises energy consumption during processing. Efficient energy use not only lowers operational costs but also enhances the economics of naphtha and LPG production. Optimising reactor designs for better thermal management can further improve conversion rates and increase product yields.
Effective heat and energy management strategies are a key consideration for lowering operational costs to make the economics of naphtha and LPG production more attractive
Leveraging data analytics can optimise production pro - cesses significantly. Utilising real-time data analytics and machine learning algorithms allows for continuous moni - toring and optimisation of production processes. Predictive maintenance and operational adjustments based on data insights can enhance overall efficiency. Additionally, devel - oping simulation models can help analyse various scenarios and optimise process parameters for maximum naphtha and LPG production. Incorporating sustainability into production processes is increasingly important. Exploring carbon capture and utili - sation technologies can minimise the environmental impact of increased production, thereby improving the sustain - ability of operations while maintaining high output levels. Investigating bio-based feedstocks and waste-to-energy technologies can also contribute to naphtha and LPG pro - duction, aligning with broader sustainability goals. In conclusion, to optimise the production of naphtha and LPG for petrochemical feedstocks, a comprehensive approach that encompasses advanced catalyst devel - opment, process optimisation, feedstock flexibility, and
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PTQ Q1 2025
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