FCC Hydrocarbon Cracking of Renewable Feeds for Lower Olefins

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Solution Overview

Problem

Existing fluidized catalytic cracking (FCC) processes primarily focus on producing high-octane gasoline and do not efficiently yield both middle distillate products and lower olefins like ethylene and propylene, especially from renewable or circular feedstocks.

Innovation Solution

A hydrocarbon cracking process that combines fossil and renewable/circular feedstocks in a fluid catalytic cracker (FCC) using a fluidized cracking catalyst, followed by steam cracking of ethane to enhance the production of ethylene and propylene, with a secondary separation system to achieve high purity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional FCC processes are used to produce high-octane gasoline, then gasoline quality is improved, but lower olefins production is insufficient

Engineering Contradiction:

Improvegasoline qualityVSAvoidlower olefins production

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The process segments the product distribution by using two distinct reaction zones: a fluidized catalytic cracker for gasoline production and a delayed coker for lower olefins production. This allows simultaneous optimization of both gasoline quality and olefins yield without compromise

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The integrated system performs multiple functions: the fluidized catalytic cracker produces high-octane gasoline while generating feedstock for the delayed coker, which in turn produces lower olefins. The regenerator provides heat to both units, creating a multi-functional system that addresses both gasoline quality and olefins production requirements

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If FCC processes are optimized for gasoline yield, then gasoline production is improved, but middle distillate and lower olefins yield deteriorates

Engineering Contradiction:

Improvegasoline yieldVSAvoidmiddle distillate and lower olefins yield

Core Design Contradiction:

ProductivityVSQuantity of substance

Solution Approach 1:

The process divides the cracking function into two separate units with different operating conditions: the fluidized catalytic cracker optimized for gasoline yield and the delayed coker optimized for middle distillate and lower olefins production. This segmentation allows each unit to maximize its specific product output without compromising the other

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The process merges the fluidized catalytic cracker and delayed coker into an integrated system where the effluent from the first unit becomes feedstock for the second unit. This combination enables simultaneous production of gasoline, middle distillate, and lower olefins in optimized quantities

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If renewable/circular feedstocks are used in conventional FCC, then sustainable ethylene production is improved, but process efficiency and purity deteriorate

Engineering Contradiction:

Improvesustainable ethylene productionVSAvoidprocess efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The process changes the operational parameters of the delayed coker to accommodate renewable/circular feedstocks, adjusting temperature, residence time, and catalyst properties to optimize ethylene yield and purity from these alternative feedstocks while maintaining high process efficiency

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The integrated system is designed to handle multiple feedstock types (fossil and renewable/circular) in the fluidized catalytic cracker, with the delayed coker serving as a universal conversion unit that efficiently processes the effluent to produce high-purity ethylene regardless of the original feedstock source

Inventive Principle:

Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The process effectively produces high-purity ethylene and propylene from mixed hydrocarbon feedstocks, including renewable sources, suitable for sustainable chemical production and certification schemes.

Implementation Method 1

catalytically cracking the mixed hydrocarbon feedstock comprising renewable/circular feedstock within a fluid catalytic cracker (FCC) by contacting the mixed hydrocarbon feedstock under suitable catalytic cracking conditions with a fluidized cracking catalyst

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

steam cracking the ethane product to produce a light steam cracked product

Methodology Applied

Scientific EffectThermal decomposition: Pyrolysis

Data Source

PatentUS20250304863A1Hydrocarbon cracking process for converting renewable/circular feeds to lower olefins

Publication Date: 2025.10.02 SHELL USA INC

AI summary

In an embodiment, a hydrocarbon cracking process for converting a mixed hydrocarbon feedstock to olefins is disclosed. The hydrocarbon cracking process includes: a) catalytically cracking the mixed hydrocarbon feedstock comprising renewable/circular feedstock within a fluid catalytic cracker (FCC) by contacting the mixed hydrocarbon feedstock under suitable catalytic cracking conditions with a fluidized cracking catalyst to produce at least a catalytically cracked gas product; b) separating the catalytically cracked gas product in a separator to produce an ethane product and ethylene; c) steam cracking the ethane product to produce a light steam cracked product; and d) recycling the light steam cracked product to the separator in step b) to produce a portion of the ethylene.