NOVEL FLUID CATALYTIC CRACKING TECHNOLOGY ― EXCELLENCE IN HEAVY FEEDSTOCK PROCESSING

摘要

Fluid Catalytic Cracking is renowned as the most complex and profitable process in the refining industry, being continuously upgraded since its dawn, in 1942. PETROBRAS Advanced Converter - PACRC- has been developed aiming to process atmospheric residue from Brazilian crude, which has 10% wt CCR, high asphaltene and nitrogen compounds content. This technology encompasses a set of proprietary technological developments as: A closed cyclone system, named PASS technology, to allow a quick separation between cracking products and catalyst, which also provides its pre-stripping; An optimized feedstock injection system, called ULTRAMIST, operating at supersonic speed with low pressure drop and a better usage of vapor energy in the oil atomization; Improvements in riser, Optimization of equipment mechanical design. FCC environmental problems and on going technologies focused on impact mitigation are discussed. It is also reported an example within the refining area of the supply chain integration, in which PETROBRAS and Fabrica Carioca de Catalisadores, a catalyst supplier, strive for synergistic solutions that resulted in the following developments: A special catalyst system, focused on improving the accessibility to larger molecules, with minimum penalties in catalyst attrition properties, resulting in better bottoms conversion and coke selectivity; Optimization of metal passivation function for a better scavenger activity; The use of flushing catalyst, cascading low metal content equilibrium catalyst for reducing the global fresh catalyst make-up. Commercial data from the two new PETROBRAS' RFCC Units are reported: Capuava Refinery (RECAP), 19,000 bpd, in Sao Paulo State, and Landulpho Alves Refinery (RLAM), 63,000 bpd, in Bahia State. Although these refineries are processing refractory feedstocks, they are providing conversion and yields to noble products similar to those obtained with more conventional feedstock. A third unit designed with the same technology at Alberto Pasqualini Refinery (REFAP) is presently under EPC phase.