Hydrocarbon Processing - December 2022 - 33

Catalysts
Qilu Petrochemical Co. and the authors' company, and its designed
processing capability is ~800,000 tpy of crude oils. The
high and low side-by-side towers are adopted as the reactionregeneration
system. The amount of catalyst added per day is
around 2.5 t, which is equivalent to the former catalyst. Considering
the standard conditions of changing catalyst and the
common cause of catalyst loss, the storage of the new catalysta
in the unit reached 100% by March 9, 2021. The catalyst change
was performed steadily without any aberrant loss of catalyst.
Two representative times were chosen to reflect the potential
of the new catalyst. The summary calibration (marked as SC)
was conducted from March 9 to March 10, 2021, using the new
catalyst, and the blank calibration (marked as BC) was from
September 11 to September 13, 2019, when the previous catalystb
was
used in the same refinery.
Properties of raw oil. The properties of raw materials exert
notable influence on catalytic performance, so it is imperative to
bring up the properties of raw materials during the calibration.
The properties of raw materials during BC and SC are shown in
TABLE 2. While the properties from both calibrations are similar,
some disparities exist. The carbon residue in SC is ~2.96%,
which is 0.96% higher than that in BC. It is supposed that the
higher amount of carbon residue would cause an increased formation
of coke. Therefore, compared to the raw materials used
in BC, those used in SC have an adverse effect on the catalytic
activity of the new catalysta
.
Basic operating conditions. The basic operating conditions
during blank calibration and summary calibration are shown in
TABLE 3. Some negligible changes exist between the two calibrations.
It should also be noted that the residue ratios in both calibrations
are high.
Properties of equilibrium catalyst (E-Cat). The E-Cat's
properties are shown in TABLE 4, including the specific surface
TABLE 4. Primary properties of E-Cat in blank calibration and
summary calibration
Blank calibration Summary calibration
Physical property
Specific surface area,
m2
× g-1
*
Specific surface area of
micropore, m2
× g-1
*
Pore volume, mL × g-1
Micropore volume, mL × g-1
Average size, μm
Chemical composition, %
Al2
O3
SiO2
Na2
O
Metal content, %
Fe
Ni
V
0.13
0.027
59.5
52.9
38.5
0.24
0.49
0.29
0.16
0.145
0.035
58.5
53.5
37.3
0.18
0.5
0.43
0.25
HC Feb 2022.indd 1
Hydrocarbon Processing | DECEMBER 2022 33
1/10/2022 3:20:00 PM
*
*
66.3
78
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area, the microporous specific surface area, the total pore volume
and the volume of micropores. The calibration is discernibly
higher than the one used in the blank calibration. The larger
specific surface area and pore size are conducive to the interaction
between the organic molecules and acid centers on the
catalyst and the diffusion of big molecules in catalyst channels,
improving the conversion of heavy oil. These results indicate
that the new catalysta
achieved the designed goal with a greater
ability for the conversion of heavy oil. It should be also noted
that a stable operation of the unit and a normal fluidization of
the catalyst were presented, which means the authors' company's
catalyst could meet the operating criteria.
Distribution of FCC products and their properties. To
present the potential of the new catalyst, the conversion, selectivity,
product distribution and properties are provided, as well.
As shown in TABLE 5, with the same operating conditions, the
yield of gasoline in the summary calibration is 45.9% (1.03%
higher than the one in blank calibration) while the yield of coke
is reduced by 0.3%-the yield of liquid products was also increased
by 1.87%. According to the processing capability and the
average prices of the raw materials and products, the cost of the
raw materials could be reduced by more than $2 MM/yr while
the profit increment from the gasoline could reach $1.8 MM/yr.
Meanwhile, the reduction in coke formation also results in
emissions of ~10,000 tpy. The new catalyst
a decrease of CO2
does ameliorate the transformation of raw materials and the disOPTIMIZE
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