HS-FCC High-severity fluidized catalytic cracking: a newcomer to the FCC family

Abstract

High-severity fluid catalytic cracking (HS-FCC) is a breakthrough technology in the refining and petrochemicals industry. It allows refineries to produce petrochemicals from heavy oils by converting a low-value refinery stream into high-value products, suitable for integrated processes. The process’s main operating features are the down flow reactor system, high reaction temperature, short residence time, and high catalyst-to-oil (C/O) ratio with a modified separator system. The unique down flow reactor system in the HS-FCC process ensures plug flow without back-mixing, allowing more selectivity toward light olefins. HS-FCC produces four times more light olefins (propylene and butene) and higher octane gasoline than conventional FCC units. Since 1999, the HS-FCC has successfully passed several phases of testing with different types of feedstock at various feed capacities. The process has been proven in a 30 barrel per day (bpd) demonstration plant at Ras Tanura Refinery, Saudi Arabia. In 2011, a 3,000 BPD HS-FCC semi-commercial plant started operating at JX Mizushima Refinery in Japan. The unit ran successfully, meeting all design objectives. A full-scale commercial unit study for a 30,000 BPD HS-FCC plant was completed by JX and Chiyoda for HS-FCC commercialization.