Project Description

HSC Catalyst FCC catalyst

Applicable Scope

HSC Catalyst is a heavy oil cracking catalyst.

Characteristics

HSC-1 Catalyst is firstly developed for #2 FCCU of SINOPEC Jinan Petrochemical. HSC-1 has higher hydrothermal stability, higher activity, better gasoline selectivity and excellent metal resistance property.

Design Philosophy

HSC-1 catalyst was formulated with high stable HSY zeolite to improve its thermal and hydrothermal stability, gasoline selectivity and bottoms cracking capability. In addition, some macropore material and metal tolerant component were also introduced into the matrix of HSC-1 catalyst to promote pre-cracking of large molecules and enhance metal resistance capability.

Property

The main specifications of HSC-1 fresh catalyst are listed in Table 1.

Table 1 Main Specifications of HSC-1 Catalyst

  HSC-1
Chemical compositions, %
Al2O3 ≥45.0
Na2O <0.35
Fe2O3 ≤0.60
Physical property
LOI, % ≤13.0
Attrition Index, %/h-1 ≤2.5
Apparent bulk density, g/ml 0.6~0.8
Specific surface area, m2/g ≥220
Pore volume, ml/g ≥0.33
Particle Distribution
0~40μm, % ≤18.0
0~149μm, % ≥89.0
APS, mm 65.0~80.0
MAT
800oC/4h, % ≥74

Commercial Reference

Commercial trial of HSC-1 catalyst was performed in SINOPEC Jinan Petrochemical. Main Properties of E-cat were shown in Table 2. Compared with base case, the 0~40μm particle content of E-cat decreased gradually after the addition of HSC-1 catalyst. It indicated that the HSC-1 catalyst has good attrition resistance ability. Although catalyst consumption decreased, MA of E-cat remained, indicating that the stability of HSC-1 catalyst was higher than that of the base catalyst.

Table 2 Main Properties of E-cat

Item Base HSC-1
Pore volume, ml/g 0.25 0.31
Specific surface area, m2/g 88 96
Apparent bulk density, g/ml 0.86 0.87
Particle size distribution (PSD), %
0~20μm 2.8 0.75
0~40μm 28.5 15.1
0~80μm 78.8 61.1
0~105μm 92.7 80.4
0~149μm 99.1 96.3
APS, μm 53.9 69.0
Metal content, μg/g
Fe 7610 7853
Na 2180 1820
Ni 9870 10220
V 3810 2010
Sb 1840 1770
Ca 2550 2680
MA, % 65.0 65.5
Catalyst consumption, kg/t 1.73 1.07

The feedstock properties, operating conditions and production distribution were listed in Tables 3~5 respectively. Comparing with base catalyst, the conversion on HSC-1 increased by 4.89%, total liquid yield increased by 0.74%, the slurry yield decreased by 1.02%, gasoline yield increased by 3.66, and LPG yield increased by 1.1%. The industrial application results show that HSC-1 catalyst had higher hydrothermal stability and bottom cracking activity, higher gasoline selectivity and excellent metal resistance property.

Table 3 Feedstock Properties

Item Base HSC-1
Density (20 ℃), g/cm3 928.6 928.7
CCR, % 4.95 4.27
S, µg/g 5183 5348
N, µg/g 1707 2308
Saturates, % 55.75 56.90
Aromatics, % 23.63 23.51
Resins, % 19.56 18.81
Asphaltenes, % 1.06 0.78
Metal Content, µg/g
Fe 7.3 10.2
Na 0.3 2.0
Ni 12.5 12.5
V 3.7 0.2
Distillations range, oC
2% 289 286
10% 349 368
30% 413 409
50% 456 457
<500 oC fraction, % 65.2 70

Table 4 Main Operating Conditions

Item Base HSC-1
Feed Rate, t/h 165 158
Regeneration air consumption, m3/min 2380 2295
Disengager top pressure, KPa 186 178
Riser outlet temperature, ℃ 500 500
Feed preheat temperature, ℃ 203 218
Suspending agents injection, t/h 9 12.5
Regenerator #1 pressure, KPa 248 239
Regenerator #1 Dense bed temperature, ℃ 700 702
Regenerator #2 Dense bed temperature, ℃ 682 685
Recycle oil, t/h 12 15
Fractionation tower top temperature, ℃ 120 117
Fractionation tower feed temperature, ℃ 489 490
The fractionator bottom temperature, ℃ 285 285
Fractionation tower top pressure, KPa 160 152

Table 5 Products Distribution

Item Base HSC-1 Difference
Product distribution, %
Dry gas 3.20 3.26 + 0.06
LPG 12.72 13.82 + 1.1
Gasoline 41.49 45.15 + 3.66
LCO 29.43 25.41 -4.02
Slurry 4.80 3.78 -1.02
Coke 8.25 8.32 + 0.07
Loss 0.11 0.26 + 0.15
Conversion, % 65.66 70.55 + 4.89
Light ends yield, % 83.64 84.38 + 0.74

Commercial Application

SINOPEC Jinan Petrochemical

Products/Grades

HSC-1 and HSC-5

 

Email: y@yzeolite.com