Exxonmobil Technology and Engineering Company

Petrochemical Research Institute

Hyung Rae Kim

Xiaochun Xu

Bing Du

Colin L Beswick

Arun K Sharma

Zhiyan Wang

Chengrong Wang

Masaaki Sugita

William J Knaeble

Prateek Mehta

Daniel J Garcia

Jihad Mohammed Dakka

Liang-Shih Fan

Ross Mabon

William Joseph Novak

Fanxing Li

Aaron Sattler

Vinit Choudhary

Kirsten E Schutt

Theodore W Walker

Ethan G Dacosta

Dario Campani

Meghan E Pierson

Yosuke Sano

Joseph Famolaro

Hyungsik Lee

Fei Wang

Dawei Wang

Liang Zeng

In various aspects, systems and methods are provided for operating an oxygen-fired catalyst regenerator with flue gas recycle and COcapture. An oxygen-fired catalyst regenerator contrasts with an air-fired regenerator. The oxygen-fired catalyst regenerator substantially reduces nitrogen within the system, which facilitates COcapture by reducing the energy required to capture CO. In various aspects, a first portion of the regenerator flue gas is passed to a COcapture system and a second portion is recycled to the regenerator. Before the flue gas is recycled or diverted to the COcapture, it is passed to various processes that remove and/or reduce SO, NO, particulate, and water content. In various aspects, a portion of the treated flue gas may be combined with substantially pure Oand recycled to the regenerator.

Oxygen fired FCC regenerator with COcapture

This disclosure relates to methods for reducing COemissions from a fluid catalytic cracking process by providing a chemical looping system comprising a regenerator and reducer reactor, an oxidizer reactor, and a combustor reactor, and by sequestering the carbon dioxide of a COand HO stream. Also, this disclosure relates to methods for reducing COemissions from a fluid catalytic cracking process by partially oxidizing catalyst coke particles in a fluid catalytic cracking regenerator reactor to produce synthesis gas, and by providing a chemical looping system comprising a reducer reactor, an oxidizer reactor, and a combustor reactor.

System to convert coke in fluid catalytic cracking process by utilizing metal oxides with in-situ COcapture

Systems and methods are provided for expanding the operating envelope for an FCC reaction system while also reducing or minimizing the net environmental COemissions associated with the FCC reaction system and/or the resulting FCC products. In some aspects, reducing or minimizing net environmental COemissions can be achieved during processing of unconventional feeds, such as feeds that are traditionally viewed as having insufficient tendency to coke in order to maintain heat balance within an FCC reaction system. In other aspects, this can correspond to expanding the production of diesel within an FCC reaction system by modifying the reaction conditions in a manner that can cause a reaction system to fall out of heat balance (relative to the heat needed to maintain a target operating temperature) even when using conventional feeds.

FCC processing with reduced CO2 emissions

Systems and methods are provided for increasing the yield of products generated during co-processing of biomass oil in a fluid catalytic cracking (FCC) system. The systems and methods can allow for increased yield by reducing or minimizing formation of carbon oxides, gas phase products, and/or coke yields during the co-processing. This can be achieved by adding a hydrogen-rich co-feed to the co-processing environment. Examples of hydrogen-rich co-feeds include high hydrogen content vacuum gas oil co-feed, high hydrogen content distillate co-feed, and/or high hydrogen content naphtha co-feed. Additionally or alternately, various types of fractions that contain a sufficient amount of hydrogen donor compounds can be used to reduce or minimize carbon oxide formation.

FCC co-processing of biomass oil with hydrogen rich co-feed

FCC processing with reduced COemissions

Systems and methods are provided for improving product yields and/or product quality during co-processing of fast pyrolysis oil in a fluid catalytic cracking (FCC) reaction environment. The systems and methods can allow for co-processing of an increased amount of fast pyrolysis oil while reducing or minimizing coke production for a feedstock including fast pyrolysis oil and a conventional FCC feed. The reducing or minimizing of coke production can be achieved in part by adding a low molecular weight, non-ionic surfactant to the mixture of fast pyrolysis oil and conventional FCC feed.

FCC co-processing of biomass oil

A method may include: providing bio waste stream wherein the bio waste stream comprises at least one bio waste selected from the group consisting of palm oil mill effluent, soapstock, and combinations thereof; introducing the bio waste effluent stream into a fluidized catalytic cracking unit; contacting the bio waste with a catalyst in the fluidized catalytic cacking unit; and cracking at least a portion of the bio waste stream to form cracked products that comprise a cracked product stream.

Upgrading bio-waste in FCC

The present disclosure provides methods and systems for co-processing a hydrocarbon feed in an FCC system with a second feed of a biomass-derived pyrolysis oil and a third feed of a plastic-derived pyrolysis oil and/or lubricant. A method of co-processing fluid catalytic cracking feeds, includes: introducing a hydrocarbon feed to a fluid catalytic cracking reactor, wherein the hydrocarbon feed comprises hydrocarbons; introducing a biomass feed to the fluid catalytic cracking reactor wherein the biomass feed comprises a biomass-derived pyrolysis oil; introducing a waste feed to the fluid catalytic cracking reactor, wherein the waste feed comprises a plastic, a plastic-derived pyrolysis oil, a lubricant, or a combination thereof; and reacting at least the hydrocarbon feed, the biomass feed, and the waste feed in the presence of one or more fluid catalytic cracking catalysts in the fluid catalytic cracking reactor to produce cracked products.

Co-processing of pyrolysis oils, lubricants, and/or plastics

Systems and methods are provided for co-processing of biomass oil with mineral coker feeds in a coking environment. The coking can correspond to any convenient type of coking, such as delayed coking or fluidized coking. The biomass oil can correspond to biomass oil with a molar ratio of oxygen to carbon of 0.24 or less on a dry basis. Such types of biomass oil can be formed from pyrolysis methods such as hydrothermal pyrolysis, and are in contrast to biomass oils formed from pyrolysis methods such as fast pyrolysis. By using a biomass oil with a molar ratio of oxygen to carbon of 0.24 or less, improved yields of light coker gas oil can be achieved in conjunction with a reduction in the yield of heavy coker gas oil.

Co-processing of biomass oil in coker

Provided is a process capable of converting the cokes on spent catalysts in a fluid catalytic cracking (FCC) process into synthesis gas. The produced synthesis gas contains high concentrations of CO and Hand may be utilized in many downstream applications such as syngas fermentation for alcohol production, hydrogen production and synthesis of chemical intermediates. A reducer/regenerator reactor for a fluid catalytic process comprising a chemical looping system to produce synthesis gas is also described.

Conversion of catalytic coke into synthetic gas from a fluid catalytic cracking (FCC) process using a chemical looping system and methods related thereto

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Basking Ridge, NJ, United States of America

Hyung Rae Kim