60 results about "Fluid catalytic cracking" patented technology

Processes and facilities for producing a recycled content organic chemical compound directly or indirectly from waste plastic. Processing schemes are described herein for converting waste plastic (or hydrocarbon having recycled content derived from waste plastic) into useful intermediate chemicals and final products. The waste plastic can be liquified before being introduced to downstream processing. In some aspects, recycled content aromatics (r-aromatics) can be processed to provide recycled content paraxylene (r-paraxylene), which can then be used to provide recycled content terephthalic acid (r-TPA) and / or recycled content polyethylene terephthalate (r-PET).

A catalyst composition and method for treating a feed including oxygen is provided. The catalyst composition includes a zeolite and a coprocessing material including an oxide of at least one of magnesium (Mg), vanadium (V), and cerium (Ce).

A fluidized catalytic cracking unit system includes: a fluidized catalytic cracking unit assembly including a first catalyst regenerator and a cracking unit, the cracking unit configured to output spent catalyst to the first catalyst regenerator; and a reformer-electrolyzer-purifier assembly comprising a reformer-electrolyzer-purifier cell, the reformer-electrolyzer-purifier cell comprising an anode section and a cathode section.

A process for upgrading a naphtha feed includes separating the naphtha feed into at least a light naphtha fraction, contacting the light naphtha fraction with hydrogen in the presence of at least one cyclization catalyst, and contacting the cyclization effluent with at least one cracking catalyst. Contacting the light naphtha fraction with hydrogen in the presence of at least one cyclization catalyst may produce a cyclization effluent comprising a greater concentration of naphthenes compared to the light naphtha fraction. Contacting the cyclization effluent with at least one cracking catalyst under conditions sufficient crack at least a portion of the cyclization effluent may produce a fluid catalytic cracking effluent comprising light olefins, gasoline blending components, or both. A system for upgrading a naphtha feed includes a naphtha separation unit, a cyclization unit disposed downstream of the naphtha separation unit, and a fluid catalytic cracking unit disposed downstream of the cyclization unit.

Assemblies and methods to enhance a fluid catalytic cracking (FCC) process associated with a refining operation, during the FCC process, may include supplying a hydrocarbon feedstock to first processing units associated with the refining operation. The assemblies and methods also may include conditioning a hydrocarbon feedstock and unit material samples, and analyzing the samples via one or more spectroscopic analyzers. The assemblies and methods further may include prescriptively controlling, via one or more FCC process controllers, based at least in part on the hydrocarbon feedstock properties and the unit material properties, the FCC processing assembly, so that the prescriptively controlling results in causing the FCC process to produce intermediate materials, the unit materials, and / or the downstream materials having properties within selected ranges of target properties, thereby to cause the FCC process to achieve material outputs that more accurately and responsively converge on one or more of the target properties.

A control system for automatic operation of a fluid catalytic cracking unit includes a reactor severity control device operable to modulate a temperature affecting volume gain within the fluid catalytic cracking unit and a controller. The controller includes a processing circuit configured to calculate the volume gain within the fluid catalytic cracking unit by comparing a volume based on one or more input oil feeds to the fluid catalytic cracking unit to a volume of one or more output oil products of the fluid catalytic cracking unit. The processing circuit is further configured to use a neural network model to generate a target severity predicted to optimize the volume gain within the fluid catalytic cracking unit. The processing circuit is further configured to operate the reactor severity control device using the target severity to modulate the temperature affecting the volume gain within the fluid catalytic cracking unit.

Systems and processes for the production of circular products, including circular olefins and circular products derived from the circular olefins, by feeding particular hydrocarbons derived from one or more feed source to steam cracking and to fluid catalytic cracking and by sending the product of steam cracking and the product of fluid catalytic cracking to an integrated separation system. The circular olefins can be used in any downstream process to produce any circular product, such as a circular product produced through polymerization, oligomerization, or hydrogenation of the circular olefins.

The present technology provides a fluid catalytic cracking (FCC) catalyst composition that includes a Y-zeolite that includes a rare earth element or oxide thereof and an alumina matrix, wherein the alumina matrix includes y-AhCb or pseudo-boehmite and a dopant; and the dopant is selected from a Group IIIB metal, Group IVB metal, Group IV A element, Group VA element, an oxide thereof, or a combination of two or more thereof.

Disclosed herein is a catalyst for use in fluid catalytic cracking comprising a zeolite material and a matrix material. In at least one embodiment, the matrix material comprises mullite at a mullite index of about 35% or greater. In at least one embodiment, a matrix surface area is less than about 150 m2 / g.

The invention relates to a method of treating a microporous crystalline zeolite, such as a Ultrastable Zeolite Y, in particular for modifying acidic properties thereof. This method comprises successive steps of: impregnating said zeolite with a solution containing a tetraalkyl ammonium hydroxide in a liquid vehicle, drying the impregnated zeolite, and contacting the dried zeolite with water vapor at a temperature of between 100 and 200 °C. The zeolite thus obtained is particularly useful for use as a catalyst in fluid catalytic cracking processes.

Disclosed herein is a phosphorus modified UZM-35 zeolite, methods of its preparation, and methods of its use in hydrocarbon conversion processes, e.g., as part of a catalyst component and / or as part of a catalyst composition. Catalyst components with phosphorus modified UZM-35, their methods of preparation, and their methods of use suitable for petroleum refining applications (e.g., hydrocarbon conversion processes such as fluid catalytic cracking and hydrocracking) are described herein. Also disclosed herein are catalyst compositions, which include phosphorus modified UZM-35 and catalyst components thereof along with at least one additional catalyst component. Methods of preparing and methods of using such catalyst compositions are also encompassed by the instant disclosure.

A method of repurposing a fluid catalytic cracking (FCC) system originally designed for cracking vacuum gas oil (VGO) may include generating a first mixture of a renewable lipid feedstock and a particulate catalyst. The first mixture may be flowed through a riser for a sufficient time for the particulate catalyst to promote partial reaction of the renewable lipid feedstock to generate a second mixture including (i) catalyst particles to which acidic reaction intermediates are sorbed and (ii) a vapor-phase intermediate composition which is essentially acid free. The second mixture may be flowed into a reactor / stripper which is partially filled with more particulate catalyst. Within the reactor / stripper, the second mixture may be contacted with particulate catalyst for a sufficient residence time for the acidic reaction intermediates to substantially completely react to generate additional vapor-phase intermediate composition. The vapor-phase intermediate composition may be disengaged from the particulate catalyst and collected.

Disclosed herein is a fluid catalyst cracking (FCC) catalyst composition that includes a first component and a second component. The first component includes zeolite Y and a first matrix that includes a metal passivating constituent. The second component includes beta zeolite and a second matrix. Also disclosed herein are methods of preparing the FCC catalyst composition and method of using the FCC catalyst composition.

Embodiments herein relate to a solution to maximize the recovery of ethylene, propylene, and aromatic rich naphtha from crude oil processing. These approaches involve treating an effluent from fluid catalytic cracking (FCC) and a steam cracker effluent to remove metals such as AsH3, PH3, Hg and impurities such as NOx and oxygen, between mixing them. The combined effluent is then cooled in a cold box and passed to various fractionators for separation of ethylene, propylene and aromatic rich naphtha.

In a fluidized catalytic cracker (FCC) unit operating in petrochemical mode, it has increased dry gas and LPG production, which creates a bottleneck in the product stream, a method is provided for completely or partially separating a light gas component from a moisture compressor suction port stream and directing it directly to an untreated fuel gas header using a system in parallel with an existing moisture compressor that includes an auxiliary compressor and a membrane separation system.

A method for completely or partially separating light gas components from a wet gas compressor suction stream and sending them directly to an untreated fuel gas header using a system in parallel with the existing wet gas compressor, in a fluid catalytic cracking (FCC) unit operating in petrochemical mode where dry gas and LPG production increases and a bottleneck occurs in the product flow, wherein the parallel system includes an auxiliary compressor and a membrane separation system.

The present disclosure relates to a process for producing lighter olefins in a fluid catalytic cracking (FCC) unit. The process enhances lighter olefin production from low-value paraffinic naphtha, thereby significantly enhancing the profitability of the FCC process.

An aviation fuel composition including an aromatic-based product generated by fluid catalytic cracking of a lipid feedstock in the presence of a fluid catalytic cracking, wherein the aromatic-based product comprises at least 50 vol. % aromatics, and a paraffinic-based product comprising normal paraffins and iso-paraffins in an amount of at least 85 vol. %. The aviation fuel composition meets the ASTM D1655-24b specification with the added requirements in Annex Al and / or the ASTM D7566-24d, Annexes A1-A8 specification requirements.

A process for upgrading a naphtha feed includes separating the naphtha feed into at least a light naphtha fraction, contacting the light naphtha fraction with hydrogen in the presence of at least one cyclization catalyst, and contacting the cyclization effluent with at least one cracking catalyst. Contacting the light naphtha fraction with hydrogen in the presence of at least one cyclization catalyst may produce a cyclization effluent comprising a greater concentration of naphthenes compared to the light naphtha fraction. Contacting the cyclization effluent with at least one cracking catalyst under conditions sufficient crack at least a portion of the cyclization effluent may produce a fluid catalytic cracking effluent comprising light olefins, gasoline blending components, or both. A system for upgrading a naphtha feed includes a naphtha separation unit, a cyclization unit disposed downstream of the naphtha separation unit, and a fluid catalytic cracking unit disposed downstream of the cyclization unit.

Disclosed herein is a catalyst component suitable for petroleum refining applications (e.g., fluid catalytic cracking and hydrocracking) that includes a MSB zeolite structure (e.g., MCM-68) and a non-zeolitic matrix. The first component may be combined with additional components into a catalyst composition. Also disclosed herein are methods of preparing the catalyst component and / or catalyst compositions as well as method of using the catalyst component and / or catalyst composition.

To provide a fluid catalytic cracking catalyst enhancing the yield of propylene in fluid catalytic cracking.SOLUTION: The fluid catalytic cracking catalyst includes in mass%: 10-30% of a binder, 10-40% of zeolite ion-exchanged by rare-earth metal, 10-60% of clay minerals and 5-30% of active matrix. The binder is a silica-based binder formed from a binder-forming component having pH of less than 1.6, and the zeolite is an FAU-type one. The content of the rare earth metal is in the range of 0.5 to 1.2 mass% in terms of rare-earth metal oxide (RE2O3).SELECTED DRAWING: None

A process is described that involves the use of a dry sorbent injection (DSI) unit or a slurry reagent injection (SRI) unit to remove sulfur compounds from flue gas. For example, flue gas from an FCC regenerator is used to make superheated and saturated steam. The flue gas is then sent to a DSI unit to remove sulfur compounds and then to an economizer (or heat exchanger) to heat boiler feed water or combustion air. Additional energy can be recovered in the economizer because the temperature is not reduced as much as in the wet scrubber process.

Systems and methods are provided for reducing or minimizing the chloride content of products generated during co-processing of a plastic feedstock (such as plastic waste) in a refinery process. The reduction in chloride is achieved by mixing the plastic feedstock with one or more additional feedstocks for co-processing in a mixing and / or holding vessel that is maintained at a dechlorination temperature that allows for decomposition of chlorine from the plastic feedstock to form HCl, while reducing or minimizing other conversion of the plastic feedstock and / or the additional feedstock. A purge gas can be passed through the mixing / holding vessel to remove the evolved HCl from the vessel. Because the dechlorination temperature is selected to reduce or minimize conversion of the feedstocks in the mixture, the amount of carbon-containing products that are removed with the purge gas can be reduced or minimized. The dechlorinated mixture of plastic feedstock and additional feedstock(s) can then be processed in a convenient refinery process, such as a thermal cracking process (e.g., coking, visbreaking, other types of pyrolysis) or a catalytic conversion process (e.g., fluid catalytic cracking).

Processes and systems for fluid catalytic cracking (FCC) of hydrocarbon feeds using a multiple riser FCC reactor are described. The conditions in each riser can be tailored for handling a different feed. For example, one riser may be configured to crack heavy hydrocarbons, such as vacuum gas oil (VGO) to yield medium and light products. Other risers may be configured to crack low and / or medium hydrocarbons to yield light olefins. Embodiments of the disclosed processes and systems may be used to provide a product spectrum that has greater amounts of light olefins.

Embodiments of the present disclosure relate to a method of processing a hydrocarbon feedstock, the method comprising: fractionating the hydrocarbon feedstock into a light stream and a heavy stream; hydrotreating the heavy stream to form a hydrotreated heavy stream; combining the light stream with the hydrotreated heavy stream to form a modified feed stream; and feeding the modified feedstream to a single fluid catalytic cracking (FCC) reaction zone, thereby producing a product stream comprising light olefins. The light stream may comprise hydrocarbons that boil at less than 343 DEG C, and the heavy stream may comprise hydrocarbons that boil at more than 343 DEG C. The FCC reaction zone may be operated in a down-flow configuration, and the FCC may be operated under high severity conditions.

To provide a needle coke raw material oil that enables the effective utilization of heavy oil, comprising a fluid catalytic cracking residue, ethylene bottom oil, and catalytic reforming residue, and the fluid catalytic cracking residue and the ethylene bottom oil and / or catalytic reforming residue. [Solution] A needle coke raw material oil comprising either or both of ethylene bottom oil and catalytic reforming residue, and fluid catalytic cracking residue, wherein the density of the needle coke raw material oil at 15°C is 1.00 to 1.40 g / cm³. 3 The kinematic viscosity at 100°C is 17 mm³. 2 A feedstock oil for needle coke, having a viscosity of 0.2 / s or less and an asphaltene content of 8.5% by mass or less.

This application relates to a catalytic cracking coke generator, a regeneration system, and a regeneration method. The coke generator, from bottom to top, includes a pre-lifting zone, a reaction zone (either a bubbling fluidized bed or a turbulent fluidized bed), and an outlet zone. The pre-lifting zone is connected to the bottom of the reaction zone and the regenerator, while the top of the reaction zone is connected to the outlet zone. At least one fuel oil inlet is provided at the outlet of the pre-lifting zone or at the bottom of the reaction zone. When the coke generator and system of this application are used in fluidized catalytic cracking reactions with high reaction heat, a coke source can be provided from the reaction system to the regenerator, solving the reaction heat balance problem without affecting the regeneration process and without damaging the physical and chemical properties of the catalyst.

The present application relates to a method for predicting the performance of a Fluid Catalytic Cracking (FCC) unit to optimize the operation of a FCC, which is essential for producing liquefied petroleum gas (LPG), propylene and naphtha, for example. The technical issue addressed herein is the difficulty in accurately predicting the yield, due to operational variables and catalyst deactivation, which affect the process efficiency. In this sense, the method includes: pre-training a model based on simulated data (BD_FCCSIM); refinement based on actual historical data (BD_Histórica); fitting the model to consider process variables and catalyst properties; validation with error and correlation metrics; and implementation in a dynamic monitoring system that automatically adjusts the operational conditions. Such hybrid model, which combined physics and neural networks, provides accurate predictions and enables real-time adjustment, thereby enhancing the efficiency and adaptability of the FCC process in response to the market demand and operational conditions.

A method of repurposing a fluid catalytic cracking (FCC) system originally designed for cracking vacuum gas oil (VGO) may include generating a first mixture of a renewable lipid feedstock and a particulate catalyst. The first mixture may be flowed through a riser for a sufficient time for the particulate catalyst to promote partial reaction of the renewable lipid feedstock to generate a second mixture including (i) catalyst particles to which acidic reaction intermediates are sorbed and (ii) a vapor-phase intermediate composition which is essentially acid free. The second mixture may be flowed into a reactor / stripper which is partially filled with more particulate catalyst. Within the reactor / stripper, the second mixture may be contacted with particulate catalyst for a sufficient residence time for the acidic reaction intermediates to substantially completely react to generate additional vapor-phase intermediate composition. The vapor-phase intermediate composition may be disengaged from the particulate catalyst and collected.

A process for producing C2-C4 olefins including the fluid catalytic cracking of a solution of a low-density polyethylene (LDPE) in a heavy vacuum gas oil in the presence of a catalyst, wherein the catalyst includes: an ultra-stable Y zeolite; and, a ZSM-5 zeolite, wherein the ZSM-5 zeolite has: a silica to alumina ratio by weight of from 40:1 to 80:1; a mesopore surface area of from 150 to 250 m2 / g, as determined by Barrett-Joyner-Halenda (BJH) desorption analysis; a mesopore volume of from 0.070 to 0.200 cm3 / g, as determined by Barrett-Joyner-Halenda (BJH) desorption analysis; and, a total acidity of from 0.25 to 0.75 mmol / g, as determined by ammonia temperature programmed desorption.