Abstract:
Objective This study aims to address the significant reduction in heavy oil cracking capacity and repeated fouling of the slurry steam generator caused by catalyst calcium poisoning in a fluid catalytic cracking (FCC) unit.
Method The phenomena, causes, and mechanisms of catalyst calcium poisoning in the unit were analyzed. Measures such as injecting an in-situ crystallized heavy oil catalytic cracking catalyst, using high-quality equilibrium catalysts as replacements, and applying crude oil decalcifying agents were implemented to address the calcium poisoning problem at its source.
Result First, after injecting 20 wt% in-situ crystallized heavy oil catalytic cracking catalyst, the heavy oil cracking capacity was significantly improved even when the calcium mass fraction in the equilibrium catalyst remained around 10,000 μg/g. Second, after using crude oil decalcifying agents, the fouling problem in the slurry steam generator was resolved when the calcium mass fraction in the equilibrium catalyst decreased to 4,000 μg/g.
Conclusion When calcium poisoning occurs in the FCC catalyst, injecting an in-situ crystallized heavy oil catalytic cracking catalyst and using high-quality equilibrium catalysts as replacements can mitigate low heavy oil conversion. The use of crude oil decalcifying agents can fundamentally resolve and prevent catalyst calcium poisoning.
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