Saudi Arabian Oil Company

Othman Taha

M Rashid Khan

Saeed Al-Alloush

Henry H Chan

A method for fluid catalytic cracking (FCC) of petroleum oil feedstock includes reacting the petroleum oil feedstock with a catalyst mixture in a reaction zone of an FCC unit to obtain a product stream including desulfurized hydrocarbon product, unreacted petroleum oil feedstock, and spent catalyst. During the reacting a process control system develops a process model based on data collected during the reacting, the process model characterizing a relationship among the feed rate of the base cracking catalyst, the feed rate of the FCC additive, the operating conditions, the composition of the product stream, and emissions from the reaction; and one or more of (i) a target feed rate of the base cracking catalyst, (ii) a target feed rate of the FCC additive, and (iii) one or more target operating conditions of the reaction in the reaction zone to reduce the emissions from the FCC unit and to increase a yield of the desulfurized hydrocarbon product in the product stream are determined.

Fluid catalytic cracking of petroleum oil with reduced emissions

Petroleum oil is catalytically cracked by contacting oil with catalyst mixture consisting of a base cracking catalyst containing an stable Y-type zeolite and small amounts of rare-earth metal oxide, and an additive containing a shape-selective zeolite, in an FCC apparatus having a regeneration zone, a separation zone, and a stripping zone. Production of light-fraction olefins is maximized by applying appropriate process control, monitoring, and optimizing systems. Mathematical process models, including neural networks, statistical models and finite impulse models are used in conjunction with advanced controllers and optimizing routines to calculate optimal settings for various parameters. Process model and historical data to test a predictive system can provide early warning of potential performance degradation and equipment failure in the FCC unit, decreasing overall operating costs and increasing plant safety.

Automation and control of energy efficient fluid catalytic cracking processes for maximizing value added products

A method and apparatus for the cracking of a petroleum oil feedstock to produce a desulfurized full-range gasoline product. The petroleum oil feedstock is contacted with a base cracking catalyst and an FCC additive in an FCC unit, wherein the catalyst includes a stable Y-type zeolite and a rare-earth metal oxide and the additive includes a shape selective zeolite. The catalyst, additive and petroleum oil feedstock can be contacted in a down-flow or riser fluid catalytic cracking unit, that can also include a regeneration zone, a separation zone, and a stripping zone. The FCC unit includes an integrated control and monitoring system that monitors at least one parameter selected from FCC operating parameters, feed rate, feedstock properties, and product stream properties, and adjusts at least one parameter in response to the measured parameter to increase production of desulfurized products.

Control of fluid catalytic cracking process for minimizing additive usage in the desulfurization of petroleum feedstocks

With an aim to optimize propylene production, petroleum oil such as gas oil is catalytically cracked by contacting the oil with catalyst mixture consisting of a base cracking catalyst containing an stable Y-type zeolite and small amounts of rare-earth metal oxide, and an additive containing a shape-selective zeolite, in a down-flow type fluid catalytic cracking apparatus having a regeneration zone, a separation zone, and a stripping zone, wherein conversion of hydrocarbon occurs under relatively severe conditions. According to this fluid catalytic cracking process, the production of light-fraction olefins such as propylene is maximized by applying appropriate process control, monitoring, and optimizing systems. Process model and historical data to test a predictive system can provide early warning of potential performance degradation and equipment failure in the FCC unit.

Advanced control of severe fluid catalytic cracking process for maximizing propylene production from petroleum feedstock

An optimization method based on statistical modeling relating NGL plant process variables. The modeling may rely on input data from process history and modeled data. The method identifies process scenarios when a compressor from an associated propane/propylene refrigeration system may be deactivated and still allow the NGL plant to achieve product specification.

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Dhahran, Saudi Arabia

Othman Taha