CAT-16-6 Intro To CRC-FCC Qunzhu Li-Luoyang Weida Petrochemical Eng Co

Cat Cracker Seminar
August 23-24, 2016

Royal Sonesta Hotel
Houston, TX
CAT-16-6 Introduction to CRC-FCC: Revolutionary FCC

Technology of Energy-saving, Emission-
reduction, Low-carbon and Profit-boosting
Presented By:
Qunzhu Li
Chairman
Luoyang Weida
Petrochemical
Engineering Co. Ltd.
BEIJING, CHINA
American Fuel & Petrochemical Manufacturers 1667 K Street, NW 202.457.0480 voice

Suite 700 202.457.0486 fax
Washington, DC www.afpm.org
20006
This paper has been reproduced for the author or authors as a courtesy by the American Fuel &
Petrochemical Manufacturers. Publication of this paper does not signify that the contents
necessarily reflect the opinions of the AFPM, its officers, directors, members, or staff. Requests
for authorization to quote or use the contents should be addressed directly to the author(s)
CAT-16-6 Page 1 2016 Cat Cracker Seminar
I. Technical Background
Catalytic Cracking Process：
Improving the yield of light oil and liquid yield is the
inexhaustible motive force of the development of
catalytic cracking technology, and the eternal theme of
petroleum refining industry.
At present: a high level

It still has enough space for improvement.

FCC with Cooled Regenerated Catalyst

Cycling（CRC) Process R&D in 2005
 Improve the selectivity of catalytic cracking reaction with

lower off gas yield and coke yield
 Realize the clean and efficient development mode with

low energy consumption and low emission
The 【Reallocation of C and H element ,
mechanism Reaction process of hydrogen self-balancing】
of FCC
reaction Diesel oil
Feedstock
Settler Gasoline
Riser reactor
Dry gas
Coke
Heavy oil Regenerator

1. Dry gas: the by-product with low value and the
Dry high hydrogen content.
gas 2. Catalytic coke: the inevitable product of catalytic
Coke reaction, favorable
3. Non-catalytic coke: the product of thermal reaction
unfavorable
In theory: should be an optimum value for the coke yield.
 Too low: it can’t remove enough carbon to produce more
light oil.
 Too high: the light oil yield could be lowered with higher
energy consumption and so on.

In fact: The yield of dry gas and coke is still very high.
There is still enough space to lower further.
Basic Reasons:
Low whole activity Thermal cracking is intensified
High reaction temp. Thermal reaction is intensified
Long reaction time Secondary reaction is intensified

S
H 2S
气体
汽油
柴油
Feedstock 原料
COKE
Slurry oil 油浆
焦炭
Complicated parallel/consecutive reaction

 Synchronous occurrence of catalytic Optimal control
cracking and thermal cracking of reaction extent

Dry gas
Liquefied gas
Feedstock
Diesel oil
Coke
Thermodynamics:
1. Catalytic cracking and thermal cracking reactions etc.
are endothermic.
2. Isomerization and aromatization reactions etc. are
exothermic.

Therefore, increasing the reaction temperature is
favorable for cracking reaction and unfavorable for
isomerization and aromatization etc. reactions.
Dynamics:
Condensation reaction of coke-formation, thermal
cracking, dehydrogenation reactions of dicycclo and
polycyclic naphthene and other non-idea reactions are
non-catalytic.
Increasing temperature is favorable for this kind of
reaction.

For commercial unit, regeneration
temperature, feed temperature, reaction
temperature and catalyst-to-oil ratio etc.
are restricted by the thermal balance and
can not be controlled independently.
Since the reaction technology of riser comes out, how to

improve catalyst-to-oil ratio to control the foregoing
parameters independently and optimally is the worldwide
technical problems .

The above worldwide problem always

troubles domestic and international
FCC workers for more than 30 years.
Many domestic and international research

institutes develop a lot of patent technologies and
proprietary technologies.
But the above worldwide technical problems
are still not solved.

How to develop flexible and

controllable the cooling technology
for regenerated catalyst?
So as to control reaction temperature, catalyst

temperature, feed temperature and catalyst-to-oil
ratio independently.

1. To reduce the catalyst temperature entering

into riser reactor, to increase catalyst-to-oil ratio;
2. To increase feed temperature, so as to improve
atomizing effect of Feed.
To realize the multi-zone optimization of riser

Riser reaction.
Reactor
To realize the optimal control of reaction extent.

Invented a FCC process with CRC
 Proposed the conception of multi-zone optimization of
catalytic cracking reaction and the optimal control of reaction
extent for the first time.
 Realized the first commercial industrialization
in the world.

Proposed and studied the optimal reaction conditions for
fluid catalytic cracking of heavy oil in commercial unit for
the first time.

Investigated and studied the relationship of
1. regenerated catalyst temperature

2. reaction temperature
3. catalyst-to-oil ratio
4. feed temperature introducing into riser etc.
1. the product distribution

2. product quality
3. energy consumption
4. catalyst consumption etc.

oil and gas product
Riser  Invented circulating method of
the cooled regenerated catalyst,
in accordance with the opera-
tion of larger Cat-oil ratio.
 Developed the regenerated

catalyst cooler with reasonable
Heavy oil structure.
regenerated catalyst cooler

● Invented optimal control method of reaction feed
and reaction temperature.
● Invented the flexible and accurate method to control

cooled regenerated catalyst temperature.
To realize the flexible-controlled and independent adjust-

ment of the regenerated catalyst temperature for the
first time .
2. Technical features
1) Uses regenerated catalyst cooling and control technology
2) Lower the regenerated catalyst temperature in pre-lifting

section of the riser
3) Take full advantage of favorable conditions of high

activity of catalyst
4) To realize high temperature regeneration , to improve the

regeneration effect and activity of catalyst.

1. Major milestones
October June September June At
2005 2007 2008 2010 present
1) The first CRC commercial unit (pilot , for gasoline-

upgrading) of 0.22 Mt/a. (October 2005)
2) The second CRC commercial u n i t (for gasoline-

upgrading) of 0.5 Mt/a.（June 2007）
3) The first commercial unit(heavy oil riser with CRC) of

0.35 Mt/a. （September 2008）

4) The seventh commercial unit (CRC-R) of 1.2
Mt/a. (June 2010)
(which symbolizes that the CRC application in large
commercial unit achieves success completely)
5) At present, there are 20 sets of commercial units

in safe and reliable operation totally, of which
maximum capacity is 2.6 Mt/a, three of which are
gasoline-upgrading technologies.

2. Application Examples
The CRC achievement of large-scale central enterprise and
others in China
Others, 5
sets ChemChina,
6 sets
CNOOC, 2
sets PetroChina,
7 sets

 Used for the present unit revamping and new plant.
 Totally 20 sets of FCCU ( max. capacity of which is

260 Mt/a ) in safe and long-period operation by the
end of 2014
 Increased the profits and taxes of RMB 5.096 billions

totally , and gained high praise of all enterprises.
For the capacity of 100 Mt/a, the annual increasing

benefits is RMB 166 millions.
The investment payback period is around 3 months.

A- Refinery: RFCC unit of 0.5 Mt/a
Feeds: Paraffin intermediate base
Reaction & regeneration structure type:

 the fast-bed series regenerator
 Second regenerator is located on the top
 the first one is coke-burning drum
 being arranged with disengager in parallel.
The key technical indexes are as follows:

Indexes Effects
Total yield of light Increased by 1.98 percentage
oil point
Decreased by 4.2 percentage
Gasoline olefin
point
Octane number Increased by 0.1 unit
Cetane number Increased by 1.0 unit
Unit consumption
Decreased by 30%
of catalyst
Energy Decreased by 16.8
consumption kgEo/t Feed
B-Refinery: RFCC unit of 1.2 Mt/a
Feeds: High sulphur fuel oil

 Disengager and regenerator are arranged coaxial
 Regenerated by single-stage regeneration.

Indexes Effects
Increased by 1.7
Total yield of light oil
percentage point
Decreased by 5.2
Gasoline olefin
percentage point
Unit consumption of catalyst Decreased by 30%
Decreased by 11.6
Energy consumption
kgEo/t Feed

C-Refinery: RFCC unit of 1.4 Mt/a
Feeds: Intermediate base

Disengager, the first regenerator, the second regenerator
are arranged in parallel.

Indexes Effects
Increased by 1.99
percentage point
Decreased by 8.72
Gasoline olefin
percentage point
Decreased by 6.73
Energy consumption
kgEo/t Feed
D-Refinery: RFCC unit of 1.2 Mt/a
Feeds: Paraffin base

 the overlapping series regeneration
 the first stage shall be on the top of the second stage,
 arranged with the disengager in parallel.

Indexes Effects
Increased by 3.1 percentage
point
Decreased by 6.72
Gasoline olefin
percentage point
Decreased by 5.92
Energy consumption
kgEO/t Feed
E-Refinery: RFCC unit of 1.6 Mt/a
Feeds: Paraffin base

 the fast-bed series regenerator,
 its second regenerator is located on the top
 the first one is coke-burning drum,
 being arranged with disengager in parallel.

Indexes Effects
Increased by 1.3
percentage point
Decreased by 8.73
Gasoline olefin
percentage point
Unit consumption of
Decreased by 30%
catalyst
Decreased by 5.7
Energy consumption
kgEO/t Feed
Oil and gas product
1. reaction technique
2. key equipment
3. optimization control
4. formed serialized complete
technology and equipment with
Riser proprietary intellectual property
Settler
reactor rights
5. the optimal reaction condition
6. high safety, reliability and
Regenerator
advancement.
CAT-16-6 Heavy oil Page 35 2016 Cat Cracker Seminar

3. of industrial operation
（1）High safety and reliability
（2）Wide application scope
（3）Leader at home and abroad
（4）Good economic benefits

Industrial operation verifies that major technical
indexes can be reached as follows:

Indexes Effects
Increased by 1.5-3
percentage point
Decreased by 5-15
Gasoline olefin
percentage point
Cetane number Increased by 1-6 unit
Unit consumption of catalyst Decreased by 15-30%
Decreased by 6-15
Energy consumption
kgEo/t feed
discharge flowrate, NOx and It is decreased
SOx content of flue gas obviously.
Good economic benefits of CRC technology
To revamp the existing FCC unit using CRC technology,

huge economic benefits mainly come from the following
four sides:
① The ②The
③ The ④The
improvement improvement
reduction of increase of
of yield of of quality of
Consumption capacity
end product end product

1.The CRC technology passed technique appraisement
organized by China Petroleum and Chemical
Industry Federation, and was highly praised by
senior expert of Chinese Academician, Yangqiye,
etc.:
① Technical innovation ：
To propose the conception of ‘the optimization of
multi-zone reaction and the control of reaction
extent for FCC of heavy oil’ for the first time.

• To develop temperature-controlled and high effective
cooling system of regenerated catalyst.
• To propose and study the necessary condition of multi-zone

optimization in riser reaction :
 suitable low-temperature regenerated catalyst
 suitable high-temperature feeds,
 suitable reaction temperature
 suitable CAT-oil ratio.

② The technology can improve the light oil yield and
product quilty for FCC of heavy oil and realize the
energy-saving and emission reduction at the same
time. It is suitable specially for processing poor-
quality heavy oil.
The innovativeness of the technology is outstanding and
at international leading level.
③ Various process technology indexes are superior to

existing FCC technology obviously.

3. Passed the industrialization demonstration organized
by China Productivity Promotion Center Association in
February 2015 and obtained high praise of senior expert
of academician, Jingyong, etc.
① The results of operation for many years show that the

operation of CRC unites is stable, safe and reliable,
smooth to deliver and flexible to adjust.

② The effect of energy-saving and emission-reduction
is obvious. It can improve the product quality and lower
the content of NOx、SOx of flue gas. The economic
and social benefits are obvious, which is at
international leading level.

③ The CRC project is in accordance with the national
industrial development policies, whose development
direction is correct with reasonable position. The CRC
project carries out systematic and in-depth theoretical
research and application experiment for the CRC
process, which lays the solid technology foundation for the
industrialization of the CRC technology.

4. It has been highly praised by Guangxi Dongyou Pitch Co.,
Ltd, Petrochina:
The CRC technology application is successful ...... the plant
is being operated normally with stable operation and flexible
regulation, whose each specification has been reached as
planned, and the good economic results have been achieved.
Total light oil yield (including LPG, gasoline and diesel) has
been increased by 2.6 percentage point, the product
distribution and product quality have been improved
significantly.

5. Highly praised by Dagang Petrochemical Company,
Petrochina:
The product distribution of unit has been optimized
after the implementation of the CRC revamping, the
product quality has improved significantly, the effect of
energy-saving is obvious, and the economic benefits are
enjoyable.

• The FCCU unit is being operated normally after the
implementation of the CRC revamping, and now is in stable
operation with flexible regulation ...... Compared with the case
before the revamping, the gasoline LPG yield has been
increased by 1.99 percentage point, the yield of light oil has
been increased by 0.31 percentage point, 6.33 KEO/t
feedstock have been reduced for the general consumption, the
olefin content of gasoline have been reduced by 8.72
percentage point, the aromatic content has been increased by
5.96 percentage point, and the sulfur content has been reduced
by 27mg / L.
the most revolutionary breakthrough of FCC
technology after the riser reactor came out
promoted greatly the revolution of FCC technology

and the overall FCC technological level at home
improved greatly the light oil yield and the economic

benefits
More than 10% of the domestic market has been

occupied in a few years.

Will lead the third revolution of FCC technology in
the world.
The wide application of CRC technology has
upgraded the product quality
 CRC technology is leader at home and abroad，of
which various indexes are superior to existing FCC
technology obviously
 Industrial operation verifies that major technical
indexes can be reached
as follows:
Indexes Optimizing effects
Increased by 1.5-3.0
percentage point
Decreased by 5-10
Gasoline olefin
percentage point
Octane number Increased by 0.2-1.0 unit
Cetane number Increased by 1-6 unit
Unit consumption of catalyst Decreased by about 30%
Decreased by 10-15
Energy consumption
kgEo/t feed
Discharge flowrate, NOx and
It is decreased obviously.
SOx content of flue gas
Luoyang Weida Petrochemical Engineering
Co. Ltd.
Qunzhu Li
Chairman
Luoyang Weida Petrochemical Engineering Co. Ltd.
BEIJING, CHINA
Tel:(0086)10-84980949
Mobile:(0086) 13511013479
E-mail:ha8528@126.com

CAT-16-6 Intro To CRC-FCC Qunzhu Li-Luoyang Weida Petrochemical Eng Co

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Cat Cracker Seminar

August 23-24, 2016

CAT-16-6 Introduction to CRC-FCC: Revolutionary FCC

American Fuel & Petrochemical Manufacturers 1667 K Street, NW 202.457.0480 voice

At present: a high level

CAT-16-6 Page 2 2016 Cat Cracker Seminar

FCC with Cooled Regenerated Catalyst

 Improve the selectivity of catalytic cracking reaction with

 Realize the clean and efficient development mode with

CAT-16-6 Page 4 2016 Cat Cracker Seminar

CAT-16-6 Page 5 2016 Cat Cracker Seminar

Low whole activity Thermal cracking is intensified

High reaction temp. Thermal reaction is intensified

Long reaction time Secondary reaction is intensified

CAT-16-6 Page 6 2016 Cat Cracker Seminar

Complicated parallel/consecutive reaction

CAT-16-6 Page 7 2016 Cat Cracker Seminar

CAT-16-6 Page 8 2016 Cat Cracker Seminar

CAT-16-6 Page 9 2016 Cat Cracker Seminar

Since the reaction technology of riser comes out, how to

CAT-16-6 Page 10 2016 Cat Cracker Seminar

The above worldwide problem always

Many domestic and international research

CAT-16-6 Page 11 2016 Cat Cracker Seminar

How to develop flexible and

So as to control reaction temperature, catalyst

CAT-16-6 Page 12 2016 Cat Cracker Seminar

1. To reduce the catalyst temperature entering

To realize the multi-zone optimization of riser

CAT-16-6 Page 13 2016 Cat Cracker Seminar

CAT-16-6 Page 14 2016 Cat Cracker Seminar

CAT-16-6 Page 16 2016 Cat Cracker Seminar

1. regenerated catalyst temperature

1. the product distribution

CAT-16-6 Page 17 2016 Cat Cracker Seminar

 Developed the regenerated

regenerated catalyst cooler

● Invented the flexible and accurate method to control

To realize the flexible-controlled and independent adjust-

2) Lower the regenerated catalyst temperature in pre-lifting

3) Take full advantage of favorable conditions of high

4) To realize high temperature regeneration , to improve the

CAT-16-6 Page 20 2016 Cat Cracker Seminar

1) The first CRC commercial unit (pilot , for gasoline-

2) The second CRC commercial u n i t (for gasoline-

3) The first commercial unit(heavy oil riser with CRC) of

CAT-16-6 Page 21 2016 Cat Cracker Seminar

5) At present, there are 20 sets of commercial units

CAT-16-6 Page 22 2016 Cat Cracker Seminar

CAT-16-6 Page 23 2016 Cat Cracker Seminar

 Totally 20 sets of FCCU ( max. capacity of which is

 Increased the profits and taxes of RMB 5.096 billions

For the capacity of 100 Mt/a, the annual increasing

CAT-16-6 Page 24 2016 Cat Cracker Seminar

Reaction & regeneration structure type:

The key technical indexes are as follows:

CAT-16-6 Page 25 2016 Cat Cracker Seminar

Reaction & regeneration structure type:

The key technical indexes are as follows:

CAT-16-6 Page 27 2016 Cat Cracker Seminar

CAT-16-6 Page 28 2016 Cat Cracker Seminar

Reaction & regeneration structure type: