549-557
-
†
,
Advanced Chemical Technology Division, KRICT, 100 Jang-dong, Yuseong-gu, Daejeon 305-600, Korea
(Received 22 March 2003; accepted 28 May 2003)
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Abstract − In the whole world, the amount of CO2 emission from the ethylene plant is about 141 million tons per year, and
currently about 40% of the energy in petrochemical industry is used for steam cracking of naphtha. So, global warming issues
have stimulated the development of new cracking process of naphtha which can minimize CO2 emission through the increase
of energy efficiency. Also there is an effort to increase the ratio of propylene/ethylene in naphtha cracking since the natural gas
cracker which can produce ethylene preferentially increases more and more. Therefore, catalytic cracking of naphtha has been
studied as an alternative of thermal cracking to balance ethylene and propylene demand and to reduce CO2 emission. This
paper will review the various routes which have been investigated and applied over the past years, but will focus particularly on
the recently patented and commercially demonstrated processes for the production of lower olefins from naphtha.
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x6®( CO2 ¯ &
y{; A°2
b. ± ($% 200-500 oC)& 3-5%/, ðw Ü#¡ á{.
g{.( Zrsvw fluid catalytic cracking[3], deep catalytic ( MN9
*96 . "# MN
cracking[4], catalytic pyrolysis[5], steam cracking[6] D -², ? · z¶ [*
Table 1 Þ9ñ², ? {© R
vw y z{9
9t { R³7 )*9, -. ³7 )*8.(º "# MN ò9, -.
´ ´µ3 z¶ d{.(
Sª +, - ó #(heavy oil)7 9t MN9
·
R³-Zrs
· ¤¥·P z¶
Sª ¸B \)/i¹8. ¦ z¶ d{.( ôªõ ¦+, -. 7 =, ö¤ Stone
(º B» ¦AB K¼9,½ . & Webster )3 Sª §QRgh(quick contact reaction)
!
cr( B9 ·÷ gh
Æ ± feed oil vÍAÄ )*9 ðø
2.
-[8, 9]. ù¤ British Petroleum )3 Sª ]
! ·÷ ,wÎ R³ gh
7 *9 ðø -,, ±´ Tokyo
2-1. Science & Technology )3 Sª
! ³( ÒZ н7 )
(naphtha cracking)¾ ¿À ]Á
3 ! & *9,, gh/mM÷ ¸Îgh
(fluidized bed reactor)7 )*9
à ; 7 750-850 oC3 9t
KL
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; ·(>·TU D MN9 gh.(3,
v cracking)
! gh úEÜ Ê û! crÊ.( üý<Þ ·÷
3 &
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(tubular piston flow reactor)7 )*9/, ± feed
· Æ ]
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Table 1. Commercialized technology for the production of light olefin from naphtha
Process Summary Inventor
Maxenetm Continuous process via adsorption/desorption for recovery of C5-C11 n-paraffin from naphtha UOP
Decomposition of n-paraffin into ethylene in a cracker
New technology from Sorbex of UOP
Ethylene yield >30% from naphtha
More than 100 technology transfers (Sorbex) in the world
Steam cracking Thermal decomposition with heterogeneous catalyst VNIIOS Co.+Russian
Catalyst : KVO3/B2O3/mullite-corundum University of Oil and
Ethylene 30-34wt%, propylene 18-20wt%@760-910 oC, LHSV=3.0-3.5h−1 Gas+Angar sk Petchem. Co
Demonstration unit 7.5t/h
RxCat Production of ethylene and propylene from the distillate containing low concentration of aromatics (>20 wt%) Upson & Nelson
Contains dual riser, dual reaction zone (under development for
Use ZSM-5 series additives from improving shape selectivity, high yield and minimized hydride transfer improved technology with
reaction during cracking UOP)
Connect catalyst recycle line and MxRTM, and connect with riser, so that suppress the formation of lower
alkanes and improve low olefin yield via second cracking
CPP (Catalytic Good for heavy feedstock Stone & Webster
pyrolysis Riser reactor containing continuous reaction/regeneration/recycle process (demonstrated in 2000)
process) Catalyst : modified zeolites with dual functions
Similar to FCC reactor/regenerator
Working at lower temperature than Steam cracking unit
Not necessary of expensive alloy for reactor
Yield : ethylene 22%, propylene 20%
Table 2. Recent technologies for the production of light olefin by naphtha cracking
Technology Summary Inventor
o
Low residence time catalytic cracking Cracking temperature: 800-1,200 F Stone & Webster
process (US Pat. 5,976,355) (1999) Residence time: 0.05-0.5 sec. (USA)
Catalyst/feedstock (wt): 3-15
Cracking pressure: 0-350 psig
Product composition: C2 1.7%, C4 49.8% etc
Conversion: 85%
Process for production of ethylene and Cracking temperature: 650-757 oC, pressure: 0.15-0.4 MPa China Petrochemical
propylene by catalytic pyrolysis of heavy Contact time: 0.2-0.5 sec. Co.
hydrocarbons (US Pat. 6,210,562) (2001) Catalyst/feedstock (wt): 15-40 (China)
Steam/feedstock (wt): 0.3-1
Catalyst: pillared clay, or Pentasil structure zeolite containing P, Al, Ca
Ethylene, propylene yield >18 wt%
Method for Producing Ethylene and Catalysts: ZSM-5 (SiO2/Al2O3=200-5,000) type zeolite containing IB elements (Cu, Ag, Au) Asahi Kasei Kogyo
Propylene (US Pat. 6,307,117) (2001) Cracking temperature: 400-700 oC, Kabushiki Kaisha
Pressure: 1-10 atm (Japan)
WHSV=1-1,000h−1
Feedstock: at least 20 wt% hydrocarbon containing one of C4-C12, or ethylene 10 wt%,
propylene 30 wt%, butene 21 wt% etc
Chemical absorption process for recovering Compress cracked gas upto 50-250 psig Stone & Webster
olefins from cracked gases (US Pat. Wash the compressed gas to remove acidic gas, performing hydrogenation, and scrubbing (USA)
6,395,952) (2002) under metal salt solution, then separation gas (paraffins) and liquid (olefins)
Separation ethylene, propylene, butene from the liquid
2-2.
@f R³-Zrs · ¦ 1960 »g? ¼2+$
², )*+ R³( NF, e
F 4 NÜ R³ D.(
+/, ! 3
F û! i3
F vw\u3 )*b(Table
4\).
n pqZrsI i¹ Ag-mordenite/Al2O3, CuH-ZSM-5,
4Ø HZSM-5 DI J! NF R³ i¹{ 5! a<, i3
Table 5. Properties of light naphtha[13] Table 6. Reaction conditions of used in the feasibility study [13]
o
Specific gravity (15/4 C) 0.643 Reaction conditions SORa EORb
Av. molecular weight 74.6 Temperarture (oC) 600 650
Sulfur (wt ppm) 30 Steam/oil feed ratio(wt) 0.5 0.5
W/Fc (kg s/m3) 620 620
Carbon number Pressure (kg/cm2 G) 1.0 1.2
C4 (wt%) 17.5 a
Start of run, bEnd of run
C5 (wt%) 59.8 Weight of catalysts (kg)/volumetric feed rate (m3/sec)
c
C6 (wt%) 30.6
C7 (wt%) 12.1 Table 7. Comparison of naphtha catalytic cracking and steam cracking [13]
Catalytic cracking Steam cracking
Composition
o
n-paraffins (wt%) 53.1 Temperature ( C) 600-650 780-870
i-paraffins (wt%) 40.3 Steam/Oil feed (wt) 0.5 0.5
naphthenes (wt%) 15.5 Pressure (kg/cm2 G) 1.0 1.0
aromatics (wt%) 11.1 Propylene/ethylene (wt) 0.67 0.44-0.66
olefins (wt%) 10.1
Yield (wt%) (in olefin max mode)
Hydrogen content (wt%) 16.4 Ethylene 34.7a (46.3)b 33.5 (38.1)
Propylene 23.4 (24.3) 17.1 (17.4)
Butene 4.5 (4.6) 4.9 (4.9)
Butadiene 0.2 (0.6) 4.6 (4.7)
a
Yield in once-through reaction
b
Overall yield after recycling of ethane/propane
Table 8. Recent patents on the catalysts for the production of light olefin from naphtha cracking
Catalyst Summary Source Inventor
1-6 wt% USY Production of LPG, C3, C4 olefins: LPG 40-65 wt%, lower olefin US Patent Indian Oil Co.
8-25 wt% Pentasil selectivity 40 wt%, 5,846,402
WHSV=40-120 h−1 (1998)
Temp.: 530-600 oC
Catalyst/feedstock (wt): 15-25
Ferrierite, faujasite, heulandite, chabazite, Catalytic cracking followed by thermal cracking for higher production US Patent Exxon
beta, ZSM-5, -11, -25 etc (SiO2/Al2O3=2-2000) of ethylene 6,033,555
Temp.: 500-750 oC (2000)
WHSV=0.1-100 h−1
Thermal cracking : 650-900 oC
Zeolite/clay/phosphate Zeolite: 0.5-40 wt%; clay: 50-94.5 wt%; phosphate 5-25 wt% US Patent Bulldog Tech.
(suitable for fixed-bed or fluidized bed reactor) Improved activity by 10% than the previous zeolite/clay/ phosphate catalyst 6,103,949 (USA)
Product: C3-, C4-olefin, i-butane etc (2000)
ZSM-5, ZSM-11, P or their mixture Conversion of C4-C7 olefin and C4-C7 paraffin into ethylene and propylene US Patent Mobil Oil
(SiO2/Al2O3>300) Zeolite: 5-75 wt%, matrix: 25-95 wt%, P: 0.5-10 wt% 6,222,087
Matrix: silica, alumina, clay or their mixture Propylene/ethylene>3 (2001)
Propylene+ethylene=20 wt%
SAPOs (FCC catalyst) Composition: Si 4-20 mol%, Al 40-55 mol%, P 30-50 mol% US Patent Exxon Mobil
AEL structure (e.g. SAPO-11) 6,409,911
Cracking 500- 650 oC (2002)
Catalyst/feed: 3-12
Feed residence time <10 sec.
Pillared clay (catalytic pyrolysis catalyst) Composition: pillared clay 30-75 wt%, metal oxide 10-40wt%, Y US Patent China
(or Pentasil) 0-30 wt%, kaolin 0-50 wt% 6,342,153 Petrochemical
Production of C2-C4 olefin (39-54 wt%) from heavy oil residual feedstock (2002) Co.
Suitable for FCC and CPP
K\* @f R³( CaO-Al2O3, KVO3/Al2O3, ZrO2/ ³ gh;², cf gh 9t MF9 æ @
Al2O3, alkali polyaluminate D Xö& æ8b R³Æ Sb/ZrO2-MgO f c gh ¼2b. 2î! R³ nm9
Æ MnO/ZrO2, K/ZrO2 D ZrO27 æ8 R³, Fe-MgO û! Mn-MgO Ñ ÷Ó Gw÷ Xöq 9t MF+ Xp N%(½v
Æ J MgO7
´.( 9 R³ D ·9t ¦+$[18-21]. ?Û) 9t MF+ .( -. R³ 9t ± M
R³ 5 è|{ 2 v^% -², R³ è| Fb ! rspP7 N%.( LN+= ¸9, w3 ÑF
k ÒZ7 l
.( -[22]. ½7 = Öx:t a(carbenium ion) +,, V ½« 2! u
Zrs P N2 EÜ .( ¼ - AÏ.( + Öx:t a.( Èy. o, t
3 ®9
F 2
NF cfgh(oxidative dehydrogenation) -[23]. ðõ ! Xp N% 9t gh ¼2+,, rspP7 N% 9
"0< & 5! a<3 á<& 0 t Ú)b(propagation) .(
b. Xp N%I rspP
È-`², Èm NÜ EF F.( F NÜ 7 N%! 3( ¿3
{/ gh ô9Û Ú). K2
gh '( )*+ R³. ðõ, V-Mg NÜ(VMgO) R³ zB -6 Xö 2î R³Z 9², 2î S
"0 (SI ?@.(? (>I ?
MF9², Kung ¼gh ]&9| ÒZ MF 6¦+,, Sb. [Q{
D[24]! 540-600 oC ùZ3 ?@.(? 55% I 58% á
<(?
+?îY)7, (S.(? 33% I 42% (>
á<7
t. ±g{.( oxidative dehydrogenation3 ghO
Table 9. Current status of naphtha cracking technologies in the world mw{ 6 )7:.
Thermal cracking Acidic cracking Catalytic pyrolysis
ABB lummus Sinopec VNIIOS
Brown & Root ABB Lummus Toyo
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¡.( 7 i _Û +=,
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