AM-13-04 Flexible Pilot Plant Technology for Evaluation of Unconventional Feedstocks and Processes

Description:

The fluid catalytic cracking process has been in commercial practice for 70+ years. Feedstocks and process designs have evolved greatly over this period. Today is a time of exciting change in the FCC world. New feedstocks such as bio-oils (vegetable and pyrolysis), and straight run shale oils are being investigated by refiners. New FCC designs such as High Severity Fluid Catalytic Cracking (HS-FCC) and Deep Catalytic Cracking (DCC) have been developed. Onpurpose olefins manufacturing processes, such as ExxonMobil PCCSM and KBR Superflex™, and use of FCC-type processes for very light feeds (including gases and light alcohols) are being proposed. These options represent significant change, and therefore significant risk. One way to minimize the risk associated with these opportunities is to conduct realistic pilot plant testing prior to commercial implementation. One pilot unit that has gained wide acceptance in mimicking commercial FCC operation is Grace's DCR™ pilot plant. Including the two DCR pilot plants operated by W.R. Grace & Co., a total of 26 licensed DCR pilot units have been constructed throughout the world. This paper includes comparisons of DCR pilot plant results to commercial FCC units for petroleum derived gas oil and resid feeds, and also describes application of the DCR pilot plant to a variety of alternative feedstocks and process designs. Testing experiences with vegetable oil, pine-derived pyrolysis oil, and straight run shale oil are described, highlighting the utility of the DCR unit in evaluating these feedstocks and understanding their effects on yields and operation. Furthermore, applications of the DCR in studying new high temperature cracking processes designed for high light olefins yields and processing very light feeds in a circulating fluidized bed are described.