RFCC Catalysts for Chemical Feedstocks

Heavy petroleum and tar sand bitumen reserves in the Western Hemisphere rival those found in the Middle East, but they have higher concentrations of sulfur, metals, and aromatics, which make them more expensive to process. One important area that has not been extensively investigated is using these heavy petroleum resources for large scale petrochemical production. This project will develop technology to enhance the performance of fluid catalytic cracking (FCC), which plays an integral role in the conversion of heavy feedstocks. The approach will be based on a new type of catalyst, which was developed previously for the FCC production of aromatics and olefins as petrochemical feedstocks. This catalyst can be formulated as part of a standard FCC catalyst or it can be used as a separate additive. In Phase I, several catalysts will be prepared and characterized, and microactivity tests will be performed. In Phase II, the most promising catalysts identified will be tested in a bench-scale reactor, and the catalyst formulation will be optimized. Then, the best catalyst will be evaluated in a pilot scale test. Commercial Applications and other Benefits as described by the awardee: The new FCC catalysts should allow heavier FCC feedstocks to be processed for the production of olefins and aromatics used in petrochemical manufacture. The petrochemical industry will be able to use heavier feeds, which will stimulate increased use of Western Hemisphere heavy oil resources.