FCE1

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Fluid catalytic cracking (FCC) is a technology used in refineries to convert heavy hydrocarbon feedstocks such as vacuum gas oils into more valuable light products such as gasoline and diesel. It is widely used in the petroleum refining process and is one of the most important conversion processes in the refining industry.

In the FCC process, a catalytically active particulate solid catalyst is used to catalyze the cracking of long-chain hydrocarbons into gasoline range (C5-C11) and light cycle oil (LCO) range hydrocarbons in a fluidized-bed catalytic cracking unit.

FCC catalysis includes the following crucial reaction steps: formation of hydrocarbon radicals, combinations of radicals and dimers to form larger molecules, and isomerization and disproportionation (breaking apart of molecules) reactions. When a heavy hydrocarbon molecule is cracked, the liberated molecule will again initiate the reaction and create additional light hydrocarbons.

The FCC process is divided into four main steps: pre-processing, catalyst processing, cracking and post-processing. During the pre-processing step, the hydrocarbon feedstock is heated to the desired reaction temperature and then introduced into the catalytic cracking unit which is filled with a working fluid catalyst. In the second step, the feedstock is atomized and introduced into the catalytic cracking unit filled with the working fluid catalyst.

The third step is the actual cracking reaction, where the feedstock molecules pass through the catalyst bed and interact with the catalyst particles to form the cracked hydrocarbons. After the cracking of the feedstock, the catalytic cracking products are removed from the reactor and a post-processing step is performed to remove any remaining catalyst and produce the desired products. The post-processing step involves purification, distillation and recovery of the cracked compounds.

Fluid catalytic cracking technology can be used to produce a wide range of products with high yields and low sulfur content. Its main advantages over other methods of hydrocarbon cracking are higher selectivity, higher yields, and lower operating costs. The main disadvantage is that the catalyst can become deactivated over time, requiring a continuous flow of fresh catalyst to stay in operation. As a result, the cost of catalytic cracking units is relatively high if compared to other processes.

Fluid catalytic cracking units (FCCUs) are the most important conversion units in petroleum refineries, providing high yields of valuable light distillates from heavier feedstocks. They can also be used to process residual fuel oils to produce lower-sulfur and more valuable distillates. FCCU technology has become increasingly important for meeting changing market demands for cleaner burning fuels as sulfur limits and other regulations are tightened.

Fluid catalytic cracking technology is used today in refineries worldwide as an effective and efficient way to process heavy hydrocarbons into valuable light products. This technology is highly capable of producing high yields of low-sulfur distillates while minimizing operating costs. Additionally, it is a relatively flexible process that can be adapted or modified to meet changing market demands and specifications.

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