Fluidized Catalytic Cracking Process Decarbonization
In this article, Stephen Jewell, Technical Advisor for KBR’s refining and clean fuels business, focuses on the results of modeling various low-capital strategies that incrementally lower Scope 1 and Scope 2 carbon dioxide (CO2) emissions. Practical changes to hardware and operations of the fluidized catalytic cracking unit (FCCU) will allow refiners to reduce the carbon footprint.
Emissions of greenhouse gases (GHG) due to human activity have increased significantly since the industrial revolution, and carbon dioxide (CO2) emitted by burning fossil-derived fuels is a key contributor. Decarbonizing the transportation and energy sectors is important to reduce GHG emissions that contribute to anthropogenic climate change. Governments worldwide have created emissions benchmarks, incentives and statutory requirements to lower the CO2 footprint of these industries.
Furthermore, carbon tax policies and carbon trading marketplaces are under development that will have large impacts and change the way these businesses conventionally run. If fossil-based liquid fuels continue to be used for transportation and energy generation, lowering the CO2 footprint of the transportation sector will remain an important long-term issue.
About FFCU
The FCCU is a heavy oil conversion process that has historically been operated to maximize yields of gasoline-range material. The FCC process has been in commercial operation since the 1940s and is acritical step in converting low-value, high-boiling point, heavy hydrocarbon fractions into lighter, high-value products, such as liquefied petroleum gas (LPG), gasoline and diesel.
The FCCU is energy-intensive and creates 20%–30% of total Scope 1 and Scope 2 CO2 emissions from a typical refinery.
Decarbonizing the FCCU requires the implementation of strategies that are specific to the FCCU, as well as approaches that can be adopted throughout the entire refinery.
The solutions available include energy efficiency improvements, energy recovery equipment, reductions in carbon intensity of utilities, hardware technology that inherently produces less CO2, and CO2 carbon capture and storage (CCS).
The key is to ensure that the FCCU and the refinery remain economically viable while reducing their CO2 footprint.
KBR’s Role
KBR has been designing and licensing FCCUs since co-designing the first commercial unit in 1942 at the ExxonMobil plant in Baton Rouge, Louisiana (U.S.). The FCC process has undergone significant shifts to improve efficiency and target greater gasoline and LPG yields—aided by hardware and catalyst technology developments—and will continue to evolve to meet market demands.
KBR offers technological solutions for refiners to improve operational and energy efficiency while increasing yields of valuable products.
To know more about this offering, read this article.
