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T
he Fastest Route to Higher Octanes The stock processing could also meet an enhanced
refinery octane pool is balanced and deter- octane objective. However, a change in the cata-
mined by the aggregate performance of lyst composition would likely also be required to
multiple process units. The octane making units enable the processing additional resid feed in the
naphtha catalytic reforming, light naphtha FCCU without exceeding some of the constraints
isomerisation, etherification, and alkylation of the operation like coke and gas make.
provide the potential for octane improvement and If the refinery is limited by wet gas compressor
optimised blending strategies that allow the refin- capacity, minimising dry gas and hydrogen
ery to comply with gasoline specifications, mainly production will create room to make other oper-
octane, aromatic content, RVP, sulphur, and ational changes to increase gasoline octane.
oxygen. However, the fluid catalytic cracking unit Reductions in dry gas or hydrogen yield can be
(FCCU), by far, provides the most flexibility. Over achieved catalytically or through optimisation of
a wide range of feed stocks, the FCCU operation operating variables. Operating changes that
and catalyst formulation can be adjusted to lower the mix zone temperature and modify heat
increase octane and meet other yield objectives. balance can help reduce dry gas. Selection of
feed stocks with reduced metal contaminants
Operating Conditions and Strategies to can impact the hydrogen and gas make by lower-
Maximise Octane ing the occurrence of dehydrogenation reactions
FCC naphtha octane can be increased by adjust- promoted by Ni, and to a lesser extent V and Fe.
ing operating conditions, such as riser outlet Additionally, incremental FCC LPG olefinicity
temperature (ROT). A general rule is that the can provide more feedstock for the alkylation
gasoline research octane number (RON) unit, which will ultimately increase the refinery
increases by 1 number for every 18F increase in octane pool. The option to boost LPG olefinicity
ROT, whereas ROT has less impact on motor may not prove as beneficial if the LPG constraint
octane number (MON). Since further octane results from a hydraulic recovery capability,
gains diminish as ROT is increased, the starting storage, alkylation capacity constraint, etc.,
base octane must be considered. downstream of the FCCU.
Moreover, unit constraints like LPG handling Operating conditions and strategies are of
capability, wet gas compressor limit, or regener- primary importance, but many refiners do not
ator temperature can limit FCC operating have the operating window to drive significant
flexibility. From an operational standpoint, increases in octane with operational moves
increasing mix zone temperature will increase alone. A more dramatic shift can be achieved
octane, but also will increase conversion, poten- with catalyst optimisation.
tially creating a challenging balancing act against
an LPG handling constraint. Driving Octane through FCC Catalytic and
Depending upon available options, economics, Additive Strategies
and refinery constraints, it might be beneficial Catalysts provide several possibilities to drive
for the refinery to consider changes in feedstock octane (see Figure 1). Optimisation of the FCC
composition to address the gasoline octane catalyst formulation can minimise hydrogen
shortfall. For example, a more aromatic feed- transfer reactions, which produce lower octane
stock would tend to provide a higher octane gasoline components in favour of isomerisation
gasoline component compared to a more or branching reactions; these, in turn, produce
paraffinic feedstock. Additional residual feed- higher octane gasoline components.
Some refiners are already minimising the themes emerge from the octane challenge:
octane loss in gasoline post-treatment units by 1. Responses are highly refinery dependent.
lowering FCC naphtha sulphur with Graces Challenges manifest differently at every refinery
GSR FCC catalyst and additives. Gasoline due to the unique combination of feedstocks,
sulphur reduction technologies with GSR cata- constraints, refinery configuration, and yield
lysts and additives can reduce FCC gasoline objectives. As such, the solutions are highly
sulphur by 20-40%, preserving octane while dependent on a solid understanding of these
meeting Tier 3 gasoline specifications. Since refinery-specific conditions.
2000, GSR catalysts and additives have been 2. Most refiners are employing a multi-faceted
used continuously around the globe to minimise approach to these challenges. More than ever,
sulphur in FCC gasoline. Yet, amid todays regu- these challenges require optimisation of the
latory environment, these products are entire refinery and not just individual units.
frequently utilised for octane preservation. 3. Communication with industry partners is an
integral part of successfully overcoming chal-
FCC Catalysts Solutions Close Partnering lenges. While our customers are focused on
with Refiners: A Key Response to the Octane octane maximisation for the foreseeable future,
Challenge the only dependable statement is that things are
Taking advantage of the flexibility that the FCC likely to change. The keys to success are estab-
unit provides is at the heart of a strategy to drive lishing systems and promoting business
higher gasoline octane. Several options exist to practices that allow refiners to quickly capitalise
increase gasoline octane barrels and refinery on market changes.
profitability. These options include operating Selection of the optimal FCC catalysts and
changes, feedstock management, catalytic opti- additives from Graces broad portfolio is the
misation, and combinations thereof. Some key fastest route to higher octanes and maximum