Catalysis 2023 Issue

shifting the fuels plants only, if location allows, to a more sustainable petrochemical feedstock provider. The FCC currently plays a dual role as both fuels and petrochemical provider. As transportation fuel demand declines, both the reformer and FCC operating modes will shift directionally to meet BTX, styrene, and olefin market demand. The next step, which is already in deep R&D analysis, is how to adjust the FCC to more of a ‘crude-to-chemical’ engine in a ‘single’ unit as compared to other technolo- gies. Future FCC operations may include more recycling of product back through additional catalytic/thermal process- ing steps than currently practised. Additionally, if the rules change, the FCC will be the location where synthetic oils can be cracked with the potential addition of partial burn and hydrogen for further circular unit value. This last point may be decades off. However, the system and infrastruc- ture are already present, with selected additions to move in this direction. A Sanjay Bhargava, Principal Consultant, KBC (A Yokogawa Company), Sanjay.bhargava@kbc.global FCC gasoline is a major component of refinery-produced gasoline. Therefore, minimising FCC gasoline production can be an important step for oil refineries to reduce Scope 3 emissions. One way to reduce FCC gasoline is to convert it to propylene, as the demand for propylene is expected to increase significantly. Therefore, FCCs could become an additional source of propylene to meet the demand. Currently, FCCs produce about 4-8 wt% propylene on

feed and have the potential to produce over 15 wt%. As a result, FCCs present the industry with a significant potential to produce more propylene while, again, reducing Scope 3 emissions. Olefin production in FCCs can be increased by several methods. Some of these include: • Operational changes with higher severities (higher riser outlet temperatures) • Naphtha injection or FCC naphtha recycle • Catalyst modifications to more olefin selective catalysts (such as smaller cell size with lower Al 2 O 3 ) •· Catalyst additives (C 3= selective ZSM-5) • Mechanical changes with available licensor technologies to accommodate higher severities. Waste-derived pyrolysis oil can also serve as a feed- stock to FCCs. These include olefinic and aromatic-free feedstocks for FCCs and will produce naphtha and olefins in FCCs. However, the contaminants in pyrolysis oil, such as nitrogen, oxygen, chlorides, iron, and calcium, are sig- nificantly higher in pyrolysis oil than typical FCC feedstocks and, therefore, need pretreatment for contaminants before consideration as an FCC feedstock. If left untreated, the contaminants will cause increased corrosion and fouling in the downstream equipment and a significant increase in catalyst consumption due to catalyst poisoning. More environmentally friendly pathways that produce lower CO 2 emissions are available for olefin production, such as waste plastics-derived pyrolysis oil facilities. However, each alternative has its pros and cons. For exam- ple, pyrolysis oil conversion to olefins requires significant

ANNIVERSARY 10 YEAR

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NOW CALLING FOR PAPERS We are now accepting presentation abstract submissions for Refining India 2023 ! Don’t miss the opportunity to bring your innovative technology, projects, insights, or case studies to the attention of senior executives and engineering representatives across India’s major refining companies!

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Submission Deadline: 28 April 2023

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Catalysis 2023