Catalytic Cracking

Catalytic cracking process was developed in

1920 by Eugene Houdry for upgradation of
residue and commercialized in 1930.
Houdry process was based on cyclic fixed
bed configuration.
There has been continuous upgradation in
catalytic in catalytic cracking process from
its incept of fixed bed technology to latter
fluidized bed catalytic cracking (FCC)

Feed and Product

The feed stock for catalytic cracking is
normally light gas oil from vacuum
distillation column.
Catalytic cracking cracks low value high
molecular weight hydrocarbons to more
value added products (low molecular
weight) like gasoline, LPG Diesel example
of petrochemical feedstock like propylene,
C4 gases like isobutylene, Isobutane,
butane and butane.

Kind of Reaction Occur

Main reactions involved in catalytic
cracking are
Cracking
Isomerisation
Dehydrogenenation
Hydrogen transfer
Cyclization
Condensation
Alkylation and dealkylation

Main Reaction

Fluid Catalytic Cracking

Feed Stock

Vacuum gas oil (VGO)

Hydro-treated VGO
Hydro-cracker bottom
Coker gas oil (CGO)
Deasphalted oil (DAO)
Reduced crude oil (RCO)
Vacuum residue (VR)
Typical feedstock consists of Vacuum and Atmosphere gas oil
but may include otherheavy stream.
Major contaminant in the feed includes carbon residue and
metals.
While FCC process feed containing up to 4% Conradson
carbon MSCC can process all kinds of feed.

Process Steps
Three basic functions in the catalytic
cracking process are:
Reaction - Feedstock reacts with catalyst
and cracks into different hydrocarbons;
Regeneration - Catalyst is reactivated by
burning off coke; and recerculated to reactor
Fractionation - Cracked hydrocarbon stream
is separated into various products like LPG
and gasoline, like light cycle oil and heavy
cycle oil are withdrawn as side stream

Reactionand Regenreation
Section
The feed to unit along with recycle streams is preheated to
temperature of 365oC-370OCand enters the riser where it
comes in contact with hot regenerated catalyst ( at
atemperature of about 640-660oC. Finely divided catalyst is
maintained in an aerated or fluidized state by the oil vapors.
The catalyst section contains the reactor and regenerator &
catalyst re circulates betweenthe two.
Spent catalyst is regenerated to get rid of coke that collects
on the catalyst during theprocess. Spent catalyst flows
through the catalyst stripper to the regenerator, where most
of the coke deposits burn off at the bottom where preheated
air and spent catalyst are mixed. Fresh catalyst is added and
worn-out catalyst removed to optimize the cracking process.

Fractination
Cracked hydrocarbon stream is separated
into various products. LPG and gasile are
removed overhead as vapour.
Unconverted product like light cycle oil and
heavy cycle oil arewithdrawn as side
stream.
Overhead product is sent to stabilsation
section where stablised gasoline is
separated from light products from which
LPG is recovered.

Opperating parameter
Raw oil feed at heater inlet : 114
cubic meter /hour
Furnace outlet temperature : 291oC
Reactor feed temperature : 371oC
Reactor Vapour temperature : 549oC

Product
Light gas -H2, C1, and C2s
LPG C3s and C4s includes light olefins
Gasoline C5+ high octane component for gasoline
pool or light fuel
Light cycle oil (LCO) blend component for diesel
pool or light fuel
Heavy cycle oil (HCO) Optional heavy cycle oil
product for fuel oil or cutter stock
Clarified oil (CLO) or decant oil: slurry for fuel oil
Coke by-product consumed in the regenerator to
provide the reactor heat demand

Catalyst
Zeolit
Spray dried micro-spherical powder

Reaction Process
Preatreatment
There are also varying amounts of
contaminants such as sulphur,
nitrogen and metals. To protect the
catalyst, feed pre-treatment by
hydrotreating is required in order to
remove contaminants and improve
cracking characteristics and yields.

The main reaction in the FCC is the catalytic cracking of

paraffin, olefins, naphthenes and side chains in aromatics.
The VGO undergoes the desired primary cracking into
gasoline and LCO.
A secondary reaction also occurs, which must be limited, such
as a hydrogen transfer reaction which lowers the gasoline
yield and causes the cycloaddition reaction.
The latter could lead to coke formation (needed to provide
heat for catalyst regeneration).

Primary Reactions
Primary cracking occurs from the
carbenium ion intermediates
(a) Olefin is formed first by the mild
thermal cracking of paraffin:
(b) Proton shift:

Primary Reactions
(c) Beta scission:
Carboncarbon scission takes place at
the carbon in the position beta to the
carbenium ions and olefins.

New form of carbenium ion reacts with

another paraffin molecule join the reaction

Beside paraffins:

1. Olefins smaller olefins

Primary Reactions

2. Alkylaromatics Dealkylation

3. Alkylaromatics Side chain cracking

Secondary Reactions
Isomerisation

The final product is the transformation of paraffins and

olefins to isoparaffins.
Cyclisation

The final result would be the cyclisation of olefins to

naphthenes and can caused cyclisation to coke.

Process Description
-endothermic reactions
- residence time =210 s

649760 C
316427 C

riser

Steam and VGO heated are fed to the bottom of the

riser.
The regenerated hot catalyst at is also fed to the bottom

Process Description
CO, CO2 , H2O, Air

482538 C
-Steam is injected into the stripper section, and the oil is
removed from the catalyst with the help of some baffles
installed in the stripper.
- The oil is stripped in this way from the catalyst and the
spent catalyst is sent to the regenerator.
-The coke in the spent catalyst is burned off in the

Process Description

-Hydrocyclones are installed to catch any solid particles

carried out in the overheated stream.
-The product gases from the reactor are sent to the
fractionator.
-The light gases are sent to the gas concentration unit.
-The filtered decant can be used as an aromatic solvent or

Advanteges of the Proses

Chage lower production of hydrocarbons to the credit of higher yields of C3
and C4 hydrocarbons, which can be used for isoparaffins, gasoline, C7-C3
alkylates , ad LPG diesel/
Lower cracking temperatures can reduce production ofdiolefins, that
improving the oxidation stability of the gasoline fractions
Higher octane ratings of gasoline by increased formation of branched
alkanes, naphthenes (cycloalkanes) and aromatics.
Higher cracking reaction rates, make smaller dimensioning of plant
equipment.
The conversion reactions of oil distillates in the catalytic cracking process
occur mainly in the vapor phase at elevated temperatures in the presenceof
a cracking catalyst
The cracking reactions occurring at the active sites of the catalystsproceed
by a carbenium ion mechanism that predominantly effects theformation of
olefins, isomeric components, and aromatics
The formation of low boiling olefins, branched alkanes, and aromatics favors
the production of gasolines with high octane levels