A Tri-Party Approach to Maximizing Propylene through Operational Excellence, Innovative Catalysts, and Hardware Design

Key Takeaways: A Tri-Party Approach to Maximizing Propylene through Operational Excellence, Innovative Catalysts, and Hardware Design

Executive Summary

Grace presented a case study on propylene yield improvements achieved by an Asian refiner through optimizing catalytic solutions for an HSFCC unit design. The holistic approach involved developing, testing, and implementing a customized catalyst solution, resulting in over 1.5 weight percent improvement in propylene yield, enhanced propylene selectivity, and reduced catalyst losses. The presentation highlighted the importance of understanding unit-specific operations and tailoring catalyst systems accordingly. The success of the trial underscored the significance of continuous collaboration and innovation in maximizing profitability for refiners, with Grace's advanced catalyst technologies playing a crucial role in adapting FCC operations to meet evolving market demands.

Speakers

Boheng Ma, Strategic Marketing Manager, W.R. Grace & Co
Ruizhong Hu, R&D Fellow, W.R. Grace & Co
Yujun Jeong, Technical Service Manager, W.R. Grace & Co
Moderator: Tyler Campbell, Associate Editor, Hydrocarbon Processing

Key Takeaways

1. Customized Catalyst Collaboration: The collaborative approach between Grace and an Asian refiner led to a 1.5% improvement in propylene yield through a customized catalyst solution for the HSFCC unit.

2. Long-Term Propylene Growth: Despite unfavorable short-term propylene economics, long-term demand is expected to grow, particularly in Asia, driven by population growth and increased living standards.

3. Tailored Catalyst Optimization: The HSFCC unit's unique downflow reactor design and high reactor outlet temperature necessitated a tailored catalyst solution to optimize propylene and ethylene yields.

4. Enhanced Selectivity Technology: Grace's Midas technology and Zavanti additive were key in achieving higher propylene and ethylene selectivity while reducing catalyst losses and improving operability.

5. Holistic Catalyst Design: The commercial trial's success underscores the importance of a holistic approach to catalyst design, with Grace securing a long-term supply agreement with the refiner.

Key Quote

The performance improvements you know that we saw at the Refiner really underscore the importance of a holistic and cohesive approach to catalyst design and optimization.

Webinar

Watch Full Webinar here.

FAQs: A Tri-Party Approach to Maximizing Propylene through Operational Excellence, Innovative Catalysts, and Hardware Design

General Information

1. What was the main focus of the webinar?
The webinar focused on maximizing propylene yield through operational excellence, innovative catalyst, and hardware design. It profiled a case study of an Asian refiner who improved their propylene yield by over 1.5 weight percent using a customized catalyst solution.

2. Who were the main speakers from Grace?
The main speakers from Grace were Boheng Ma, strategic marketing manager; Roizang Hu, R&D fellow; and Yu Jin Jiang, technical service manager.

Propylene Market Outlook

1. What is the expected trend for propylene demand through 2050?
Propylene demand is expected to grow globally through 2050, with the highest growth anticipated in Asia and China due to a growing population and increased standard of living.

2. What are the main drivers for the growth in propylene demand?
The main drivers for the growth in propylene demand are the increasing need for consumer goods such as packaging, automotive, and construction materials, which heavily rely on propylene.

Catalyst Optimization Project

1. What were the key objectives of the catalyst optimization project?
The key objectives were to improve olefins selectivity for both propylene and ethylene, improve the cat oil ratio to enhance overall light olefins yield, and reduce catalyst losses to improve operability and cost.

2. What approach was taken to develop the optimized catalyst solution?
The approach involved understanding the unique aspects of the HSFCC unit design, optimizing the base catalyst to generate gasoline olefins, and using a high activity ZSM 5 additive to crack those olefins into propylene and ethylene.

Commercial Trial Results

1. What were the results of the commercial trial?
The commercial trial achieved a 1.58% improvement in propylene yield, along with improvements in ethylene yield, higher selectivity for light olefins, reduced dry gas yield, and increased cat oil. The trial also showed higher unit retention and lower catalyst losses.

2. How did the trial results compare to lab tests?
The trial results matched well with previous lab test results, demonstrating higher propylene and ethylene yields along with lower dry gas and coke production.

Technological Insights

1. What are the advantages of producing propylene from FCC compared to alternative processes?
Producing propylene from FCC has a lower cash cost, lower carbon intensity, and greater operational flexibility compared to alternative processes like steam cracking and PDH.

2. What factors influence propylene yield in FCC operations?
Factors influencing propylene yield include feedstock characteristics (such as hydrogen content and metals content), operational conditions (like temperature and hydrocarbon partial pressure), and the catalyst system used.

Blog: Maximizing Growth and Efficiency in the Global Propylene Market

Maximizing propylene yield has become a strategic priority for refiners worldwide due to its critical role in producing consumer goods, packaging, and automotive components. With rising demand, refiners are exploring innovative solutions to enhance production capabilities. This blog delves into optimizing propylene yield through operational excellence, advanced catalyst technology, and strategic hardware design. Recent advancements in catalytic systems, particularly in Fluid Catalytic Cracking (FCC) units, have significantly improved refining processes. FCC units, known for their flexibility, are crucial in transitioning from traditional fuel production to petrochemically focused operations. The integration of advanced catalyst systems has enhanced the yield of valuable products like propylene and ethylene while improving overall operability by reducing catalyst losses. Continuous innovation and collaboration between technology providers and refineries are essential for achieving these optimization goals.

Growth Strategies in the Global Propylene Market

The global propylene market is set for significant growth, especially in Asia and China, driven by increasing population and improved living standards. Despite economic uncertainties and geopolitical tensions, the long-term outlook for propylene remains strong. Refiners aiming to capitalize on this trend must navigate a complex landscape of production technologies. Propane Dehydrogenation (PDH) units are gaining traction, while Fluid Catalytic Cracking (FCC) continues to be a cost-effective method due to its integration within the refinery value chain and lower utility costs.

To maximize propylene yield, a holistic approach is essential, including optimizing the catalyst system to enhance olefin selectivity and reduce catalyst losses. A case study with an Asian refiner demonstrates the importance of collaboration between refiners and catalyst providers. Tailoring the catalyst solution to the specific design and operational parameters of the High Severity Fluid Catalytic Cracking (HSFCC) unit led to significant improvements in propylene yield and selectivity, highlighting the value of a customized approach.

The HSFCC unit design presents unique challenges and opportunities for catalyst optimization. Unlike traditional riser reactors, the downflow reactor design minimizes back-mixing, allowing for a narrower residence time distribution and improved selectivity. The high reactor outlet temperature requires a short contact time to minimize dry gas formation. Optimizing pore size distribution and enhancing the activity of the ZSM-5 additive enables refiners to convert gasoline olefins into desired light olefins, thereby maximizing propylene yield.

Optimizing FCC Unit Performance and Efficiency

The success of recent FCC unit trials underscores the importance of strategic planning and execution. A comprehensive roadmap and various checks and mitigation plans ensure smooth operations during turnover periods. The trials have shown a 1.58% increase in propylene production from cracking short gasoline molecules, a reduction in dry gas yield, and an increase in naphtha octane number, indicating a more efficient catalytic cracking process. These results align with previous lab tests, reinforcing their reliability.

From a technical perspective, the trials highlight the significance of understanding each FCC unit's specific characteristics. Optimized catalyst systems tailored to target yields have led to significant performance improvements. The trials also addressed customer concerns about higher catalyst loss by maintaining stable operations and improving light olefin selectivity. Continuous monitoring and analysis of unit performance post-trial have validated the results and increased refiner confidence in the optimized catalyst system.

Advancements in FCC catalyst technology offer a competitive edge in environmental impact. FCC operations have lower carbon intensity compared to steam cracking and propane dehydrogenation (PDH) due to their lower operating temperatures. This is crucial as the industry faces increased scrutiny over carbon emissions. Additionally, the flexibility of FCC units allows refineries to adjust operations based on market conditions, providing a strategic advantage over less adaptable technologies.

Maximizing propylene yield requires a strategic combination of advanced catalyst technology, customized hardware design, and operational excellence. Refiners must adopt forward-thinking approaches, utilizing the latest innovations in catalyst development and unit design to enhance their competitive edge and profitability while meeting global market demands. Success depends on collaboration, customization, and understanding the unique dynamics of each refining operation. Integrating advanced catalyst systems in FCC units is vital for improving refining operations, profitability, and sustainability. Continuous innovation and tailored solutions, supported by collaboration between technology providers and refineries, will ensure resilience and competitiveness in the face of evolving market demands and environmental challenges. Lessons from these initiatives will guide future advancements in catalytic solutions, enabling refineries to thrive in a dynamic industry landscape.