Report Octane boosting

Why we need octane boosting in FCC: Many kinds of hydrocarbon are produced from the FCC process because many reactions such as resolution, aromatization, and isomerization take place at the same time beside the main cracking reaction. A property of FCC gasoline is determined from the ratio of each component. The octane number which is one of the most important properties of FCC gasoline is peculiar to each compound. Olefins and aromatic compounds indicate higher octane number than the others. For example, 2-hexene and benzene have higher octane number than hexane and 2-methylpentane. Meanwhile, the octane number in FCC gasoline depends on the range of its boiling point. FCC gasoline generally consists of naphtha which has the range of boiling point from 293-473K. The octane number in FCC gasoline fraction with the boiling point under 348K is higher than that over 423K because of its high olefin content. Meanwhile, the fraction with the range of boiling point from 348K to 423K shows the lowest octane number due to its high content of paraffin which shows low octane number. It is important for the octane number enhancement in FCC gasoline to increase the content of the fraction with low boiling point or to decrease the fraction with middle boiling point.

The techniques of octane number enhancement in FCC gasoline: Addition of ZSM-5: Addition of ZSM-5 additive enhances the octane number in FCC gasoline by Over-cracking of gasoline fraction. This reaction mainly occurs on the stronger acid site of ZSM-5 than that of USY. The yield of LPG is increased by overcracking and the octane number is enhanced for the mixed catalyst, though the yield of FCC gasoline is decreased. The increase of LPG yield is due to production of propylene in the case of mixed catalyst. The octane number enhancement is achieved by overcracking of the middle boiling point fraction with low octane number. Increase of reaction temperature: The octane number in FCC gasoline can be enhanced with the control of operating conditions on FCC process. There are several factors in operating conditions on FCC process such as contacting time, catalyst/oil ratio, and catalytic circulation rate and so on. The increase of reaction temperature is more effective on the octane number enhancement in FCC gasoline than the other factors. The content of aromatic compounds in FCC gasoline is increased as the reaction temperature increases because the heavier aromatic compounds in FCC feedstock are converted into the lighter fractions. Therefore the increase of reaction temperature enhances the production of high octane number fractions followed by the octane number enhancement in FCC gasoline. However, the range of reaction temperature is

restricted by the capacities of each unit in FCC process such as regenerator, gas scrubber, and heating furnace. High Octane number type of catalyst: The octane number enhancement can be achieved by the improvement of FCC catalyst without any change of the operating condition and the decrease of FCC gasoline production. Hydrogen transfer reaction, which accelerates paraffin production with the reaction of the cracked olefin with another one or a naphthenic compound occurs in conventional FCC process, and reduces the octane number in FCC gasoline. It has been reported that the hydrogen transfer reaction occurs on the acid site of FCC catalyst and the extent of the reaction depends on the density of acid site. This density of acid site can be controlled with the amount of rare earth metal in FCC catalyst. FCC catalyst with low amount of rare earth metal shows low density of acid site and thus prevents the hydrogen transfer reaction. However, the decrease of the rare earth metal causes the decrease of cracking activity because the rare earth metal stabilizes the structure of USY zeolite which maintains the acid site. To solve these problems, scientists have developed a high octane number type of FCC catalyst based on a new concept of the reduction of rare earth metal without any loss of the cracking activity. The development of this catalyst can be carried out by three approaches as follows: 1. The improvement of hydrothermal stability of USY zeolite with the increase of Si/Al ratio in zeolite structure by means of calcinations 2. The increase in weight of USY zeolite in FCC catalyst 3. The increase in weight of alumina with larger pore than USY zeolite in FCC catalyst for acceleration of heavy fractions cracking