RSC Series Catalyst FCC catalyst
RSC series are bottom cracking FCC catalysts for reducing slurry and coke yield. RSC-2006 is especially applicable for inferior heavy oil with low saturates content and high metal content.
RSC series have excellent bottom conversion, high light ends yield, low slurry and coke yield and good metal resistance.
RSC series had been developed for cracking heavy oil to reduce slurry and coke yield based on the SDM (silica-dominated matrix) technology platform. The SDM was designed to be easily accessible to the large hydrocarbon molecules by optimizing its porosity. The SDM was prepared with high activity to effectively pre-crack the inferior feeds which are difficult to crack. The SDM contains some components which can improve its metal tolerance ability. The pore structure, activity and metal tolerance ability of the SDM can be tuned easily to meet the feeds and processing demands by varying its components and preparing process. Some zeolite modification technology , for example, withdrawing aluminum and replenishing silicon technology, cleaning channels technology, optimizing exchange degree and intra-crystal position of rare earth technology, had been applied to RSC series catalysts to ensure their high activity, good thermal and hydrothermal stability and excellent selectivity.
The main specifications of RSC series catalysts were shown in Table 1.
Table 1 Main Specifications of RSC Catalyst
|Chemical components, m%|
|Attrition Index , m%/h||≤3.0|
|Apparent Bulk Density, g/cm3||0.6-0.8|
|Surface Area, m2/g||≥220|
|Pore Volume, ml/g||≥0.30|
|MAT(800℃,100% steam, 4h), %||≥72|
RSC-2006 catalyst was applied in the RFCC unit of SINOPEC Jingmen Petrochemical in 2006. The properties of the feedstock of the RFCC are listed in Table 2.
Table 2 Feedstock Properties
|C Content, m%||86.42||86.20|
|H Content, m%||12.19||11.64|
|N Content, µg/g||3900||6000|
|S Content, µg/g||7900||7700|
|Metal Content, µg/g|
The feedstock of the RFCC in Jingmen Petrochemical is inferior heavy oil. The density is about 0.93g/cm3; the hydrogen content is about 12m%; The saturate content is less than 50 v%; the content of aromatics and resins is more than 50 v%; The total metal content is more than 30 μg/g.
The major operating conditions are listed in Table 3.
Table 3 Main Operating Conditions
|Feed rate, t/d||2097||2208|
|Temp. in 1st regen., ℃||678||692|
|Temp. in 2nd regen., ℃||684||681|
|Reactor pressure, MPa||0.19||0.19|
|Recycled HCO rate, t/h||2||2|
Compared with the base case, the feed rate for the case with RSC-2006 catalyst increased significantly by 5.3% from 2097t/d to 2208t/d, as a result coke make reduced. The riser outlet temperature (ROT) is increased by 4℃ from 502℃ to 506℃, and other operating conditions are comparable.
The equilibrium catalyst properties are listed in Table 4.
Table 4 Main Properties of E-cat
|Total PV, ml/g||0.16||0.18|
|Matrix PV, ml/g||0.12||0.14|
|Metal Content, µg/g|
The total metal content on the equilibrium catalysts is more than 25000µg/g. The matrix PV of e-cat of RSC-2006 is larger than that of base catalyst, for the SDM has larger mesopore volume. Other properties of e-cat of RSC-2006 are comparable with those of base catalyst.
The product slates of commercial performance are listed in Table 5. RSC-2006 catalyst improves the products slate in slurry yield, coke make and high value products yield. First of all, RSC-2006 catalyst reduces the slurry yield significantly. The slurry yield decreases by 2.87%, from the base case 7.62% to RSC-2006 case 4.75%. Second, RSC-2006 catalyst reduces coke make by 0.52% from the base case 9.75% to RSC-2006 case 9.23%. Finally, more high value products are produced. The total yield of LPG, gasoline and diesel increases by3.77% from the base case 77.30% to RSC-2006 case 81.07%.
Table 5 Products Distribution
|Product yields, %|
|Light ends yield, %||77.30||81.07||+ 3.77|
In conclusion, for processing inferior feedstock, RSC-2006 catalyst performs efficiently on bottom cracking, coke selectivity and high value products yield.
The products properties are listed in Table 6.
Table 6 Products Properties
|Density (20℃), g/cm3||0.715||0.720|
|Sulfur content, m%||0.108||0.101|
|Aromatic content, v%||16.0||18.0|
|Olefin content, v%||43.9||40.9|
|Benzene content, v%||0.52||0.61|
|Inductive period, min||537||736|
|Density (20℃), g/cm3||0.927||0.924|
|Freezing point, ℃||-10||-6|
|Sulfur content, m%||0.69||0.58|
|Density (20℃), g/cm3||1.036||1.057|
|Saturates content, m%||34.38||15.53|
For the case with RSC-2006 catalyst, the RON and MON of gasoline increased slightly. The cetane number of diesel increased 1.8 from 25.7 to 27.5. The slurry became worse, resulting in an increased density and a decreased saturates content.
Since 2006, RSC series have been used in #1 and #2 FCCU of SINOPEC Jingmen Petrochemical, #1 FCCU of SINOPEC Yanshan Petrochemical, #2 FCCU of SINOPEC Luoyang Petrochemical.
RSC-2006 and RSC-1