The Fluid Catalytic Cracking (FCC) process has been evolving continuously, starting in the 1940's as the main Gasoline machine, taking on the additional task of converting residual feedstock's in the 1970's, and now also playing an increasing role in the production of light Olefins.
Recent innovations in FCC Process and FCC Catalysis and synergistic combinations thereof are emerging which enhance the capabilities for the production of light Olefins, while maintaining the robustness of the process for resid conversion and/or distillate fuels production.
The increasing importance of the production of Olefins in the FCC must and can be made congruent with the trends in future specifications and compositions of transportation fuels, of which the FCC remains an important producer of intermediates (Alkylate, MTBE, Isomerate, FCC Gasoline, FCC Light Cycle oil)
Propylene Demand and Supply Several drivers are affecting the growing need for the production of Propylene by Fluid Catalytic Cracking. On one hand the need for Propylene is growing faster than that of ethylene, while on the other hand the co-production of Propylene from steam crackers (~70% of supply) is expected to decline as plants are optimized to produce higher-value ethylene.
Also Ethylene, Butylenes and possibly in future also C5 (iso)olefins are or will become higher valued specialty products from the refinery and hence the FCC.
The bulk of the additional Propylene will need to be produced from changing the ratios of FCC product streams. This involves optimization of the base catalyst system and the application of small pore zeolites containing additives and catalysts in order to at least double the Propylene yields.
Moreover, addition of new technologies will be needed to further increase the Propylene production. It has been even suggested that "on-purpose" Propylene technologies may become economically viable, including dehydrogenation and the conversion of methanol to Olefins1.
Shifts in transportation fuels Changes in fuels and fuels specifications are having a great impact on the refinery. In Europe for instance due to the growth of diesel consumption there are several refineries, which are attempting to reduce their Gasoline yield because of structural over supply. Also the traditional quality of FCC Gasoline is no longer acceptable for the Gasoline pool due to the tighter Sulfur and Olefins specifications being introduced2.
In Europe because of the "dieselization" the drive to reduce Gasoline has many refiners working on ways to convert FCC to lighter Olefins (C3=, C4=). In certain cases Gasoline may be reconstructed via high severity Catalytic Cracking to Light Olefins and iC4 followed by Alkylation, BLOCK 2 - - FORUM 13 531 INNOVATIONS IN PRODUCING LIGHT OLEFINS BY FLUID CATALYTIC CRACKIN