Abstract

In the present review, historical data concerning Brazilian oil market in the last three decades are presented and discussed compared to the world scenario. Although the FCC capacity have been increasing along the years, the quality of the processed feed has been deteriorating. The evolution of the FCC catalysts technology was of paramount importance to the production chain, adapting market offer to demand.

The evolution in catalyst technology was a driving force to the development of new evaluation procedures.

Besides, changes in the evaluation procedure of catalysts and development of additives played an important role in this history.

The data discussed in this paper, strongly indicate that the FCC catalyst (combined with process improvements) plays an essential role in cracking heavier feeds, minimizing metals effect and changing product selectivities to adequate market offer to demand.

Introduction

Fluid Catalytic Cracking (FCC) is the most important refinery operation, which converts heavy feedstocks into more valuable products, adapting market offer to demand. The proper catalyst selection is of paramount importance for the optimization of FCC units. Changes in quality of feedstocks and environmental constraints are key driving forces that have changed both catalyst formulation and catalyst evaluation procedures.

Zeolite containing FCC catalysts were introduced in PETROBRAS in the 70's and at that time, catalysts were evaluated in both laboratory and pilot plant riser units. Nowadays, many of PETROBRAS FCC units operate with short contact time riser reactors and catalyst evaluation rely on multiple tests in fully automated fixed fluidized bed units operating in short contact time.

Furthermore, statistical criteria for outlier detection are also performed in a routine basis.

The characteristics of Brazilian feedstocks, which are heavy and contain high levels of basic nitrogen and contaminant metals motivated major changes in catalyst formulations, as well as in the procedures to simulate equilibrium catalysts prior to test. Finally, additives to enhance light olefins production, to increase the CO combustion, to reduce NOx and SOx emissions and to reduce sulfur in gasoline are becoming more important and have an impact on catalyst evaluation.

The present paper starts with an overview of Brazilian production/demand market for oil and its major derivatives. The increase in FCC capacity as well as the changes in the quality of the processed feedstocks is presented and discussed together with the major improvements in FCC catalyst formulations and evaluation procedures over the 30 past years.

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FCC OPTIMIZATION REVIEW: CATALYST IMPACT ON THE PRODUCTION CHAIN Brazilian Market The o
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