Research progress on reuse of fluid catalytic cracking waste from oil refinery in cement-based materials

Present paper present the main results obtained in the scope of an ongoing project which aims to contribute to the valorization of a waste generated by the Portuguese oil company in construction materials. This waste is an aluminosilicate with high pozzolanic reactivity. Several different technological applications had already been tested with success both in terms of properties and compliance with the corresponding standards specifications. Namely, this project results already demonstrated that this waste can be used in traditional concrete, self-compacted concrete, mortars (renders, masonry mortar, concrete repair mortars), cement main constituent as well as alkali activated binders.

New geopolymeric binder based on fluid catalytic cracking catalyst residue (FCC)

This paper provides information about the synthesis and mechanical properties of geopolymers based on fluid catalytic cracking catalyst residue (FCC). FCC was alkali activated with solutions containing different SiO2/Na2O ratios. The microstructure and mechanical properties were analysed by using several instrumental techniques. FCC geopolymers are mechanically stable, yielding compressive strength about 68 MPa when mortars are cured at 65 degrees C during 3 days. The results confirm the viability of producing geopolymers based on FCC. (C) 2012 Elsevier B.V. All rights reserved.

Alkali activated materials based on fluid catalytic cracking catalyst residue (FCC): Influence of SiO2/Na2O and H 2O/FCC ratio on mechanical strength and microstructure

Reuse of industrial and agricultural wastes as supplementary cementitious materials (SCMs) in concrete and mortar productions contribute to sustainable development. In this context, fluid catalytic cracking catalyst residue (spent FCC), a byproduct from the petroleum industry and petrol refineries, have been studied as SCM in blended Portland cement in the last years. Nevertheless, another environmental friendly alternative has been conducted in order to produce alternative binders with low CO2 emissions. The use of aluminosilicate materials in the production of alkali-activated materials (AAMs) is an ongoing research topic which can present low CO2 emissions associated. Hence, this paper studies some variables that can influence the production of AAM based on spent FCC. Specifically, the influence of SiO 2/Na2O molar ratio and the H2O/spent FCC mass ratio on the mechanical strength and microstructure are assessed. Some instrumental techniques, such as SEM, XRD, pH and electrical conductivity measurements, and MIP are performed in order to assess the microstructure of formed alkali-activated binder. Alkali activated mortars with compressive strength up to 80 MPa can be formed after curing for 3 days at 65°C. The research demonstrates the potential of spent FCC to produce alkali-activated cements and the importance of SiO2/Na2O molar ratio and the H2O/spent FCC mass ratio in optimising properties and microstructure. © 2013 Elsevier Ltd. All rights reserved.

Implementação de um tuboexpansor na refinaria do Planalto Paulista – REPLAN com objetivo do aproveitamento da energia contida nos gases residuais do FCC – Fluid Catalytic Cracking na geração de energia elétrica

The steel type AISI 4130 (ultra-high strength steel) is an alloy of low carbon and its main alloying elements are chromium and molybdenum, which improves the toughness of the weld metal. It has numerous applications, especially where the need for high mechanical strength. It is widely used in equipment used by the aviation industry, such as cradle-tomotor, and this is the motivation for this study. Cots are of fundamental importance, because the engine supports and maintains balance in the fixed landing gear. This equipment is subjected to intense loading cycles, whose fractures caused by fatigue are constantly observed. Will be determined the effects caused by re-welding the structure of aeronautical equipment, and will also study the microstructure of the metal without welding. The studies will be done on materials used in aircraft, which was given to study. The results provide knowledge of microstructure to evaluate any type of fracture that maybe caused by fatigue. Fatigue is a major cause of aircraft accidents and incidents occurred, which makes the study of the microstructure of the metal, weld and re-solder the knowledge essential to the life of the material. The prevention and control of the process of fatigue in aircraft are critical, since the components are subjected to greater responsibility cyclic loading

Refinery Nonconventional Feedstocks: Influence of the Coprocessing of Vacuum Gas Oil and Low Density Polyethylene in Fluid Catalytic Cracking Unit on Full Range Gasoline Composition

Gasoline coming from refinery fluid catalytic cracking (FCC) unit is a major contributor to the total commercial grade gasoline pool. The contents of the FCC gasoline are primarily paraffins, naphthenes, olefins, aromatics, and undesirables such as sulfur and sulfur containing compounds in low quantities. The proportions of these components in the FCC gasoline invariable determine its quality as well as the performance of the associated downstream units. The increasing demand for cleaner and lighter fuels significantly influences the need not only for novel processing technologies but also for alternative refinery and petrochemical feedstocks. Current and future clean gasoline requirements include increased isoparaffins contents, reduced olefin contents, reduced aromatics, reduced benzene, and reduced sulfur contents. The present study is aimed at investigating the effect of processing an unconventional refinery feedstock, composed of blend of vacuum gas oil (VGO) and low density polyethylene (LDPE) on FCC full range gasoline yields and compositional spectrum including its paraffins, isoparaffins, olefins, napthenes, and aromatics contents distribution within a range of operating variables of temperature (500–700 °C) and catalyst-feed oil ratio (CFR 5–10) using spent equilibrium FCC Y-zeolite based catalyst in a FCC pilot plant operated at the University of Alicante’s Research Institute of Chemical Process Engineering (RICPE). The coprocessing of the oil-polymer blend led to the production of gasoline with very similar yields and compositions as those obtained from the base oil, albeit, in some cases, the contribution of the feed polymer content as well as the processing variables on the gasoline compositional spectrum were appreciated. Carbon content analysis showed a higher fraction of the C9–C12 compounds at all catalyst rates employed and for both feedstocks. The gasoline’s paraffinicity, olefinicity, and degrees of branching of the paraffins and olefins were also affected in various degrees by the scale of operating severity. In the majority of the cases, the gasoline aromatics tended toward the decrease as the reactor temperature was increased. While the paraffins and iso-paraffins gasoline contents were relatively stable at around 5 % wt, the olefin contents on the other hand generally increased with increase in the FCC reactor temperature.

Conversion of low density polyethylene into fuel through co-processing with vacuum gas oil in a fluid catalytic cracking riser reactor

In this work, mixtures of vacuum gas oil and low density polyethylene, a major component of common industrial and consumer household plastics, were pyrolytically co-processed in a fluid catalytic cracking (FCC) riser reactor as a viable alternative for the energy and petrochemical revalorisation of plastic wastes into valuable petrochemical feedstocks and fuel within an existing industrial technology. Using equilibrium FCC catalyst, the oil–polymer blends were catalytically cracked at different processing conditions of temperatures between 773 K and 973 K and catalyst feed ratios of 5:1, 7:1 and 10:1. The influence of each of these processing parameters on the cracking gas and liquid yield patterns were studied and presented. Further analysed and presented are the different compositional distributions of the obtained liquids and gaseous products. The analysis of the results obtained revealed that with very little modifications to existing process superstructure, yields and compositional distributions of products from the fluid catalytic cracking of the oil–polymer blend in many cases were very similar to those of the processed oil feedstock, bringing to manifest the viability of the feedstock co-processing without significant detriments to FCC product yields and quality.

FCC-yksikön NOx-päästöjen hallinta

Työssä tutkittiin typen oksidien (NOx) päästöjen muodostumista ja NOx-päästöjen poistomenetelmiä leijukatalyyttisessa krakkausyksikössä (FCC). Koeajossa Porvoon öljynjalostamon FCC-yksikössä tutkittiin NOx-päästöjen hallintaa CO-promoottorin (CO:n palamista edistävä lisäaine) annostelun avulla. Kirjallisuusosassa käsiteltiin NOx-päästöjen muodostumista FCC-yksikön regeneraattorissa. Katalyyttisten lisäaineiden vaikutusta NOx-päästöjen muodostumiseen tarkasteltiin laajasti. Katalyyttisten lisäaineiden ohella käsiteltiin muitakin NOx-päästöjen poistomenetelmiä. Koeajojen tarkoituksena oli optimoida FCC-yksikön katalyyttikiertoon annosteltavan CO-promoottorin määrä. CO-promoottorin sisältämä platina lisää NOx-päästöjen muodostumista regeneraattorissa, mutta vähentää jälkipalamista. Jälkipalamisen vuoksi regeneraattorin ylimenolinjan lämpötila nousee. Regeneraattorin ylimenolinjan lämpötila oli CO-promoottorin vähentämistä rajoittava tekijä, NOx-päästöjä pyrittiin vähentämään ilman merkittävää jälkipalamisen kasvua. Tuorekatalyytin platinapitoisuuden pienentäminen vähentää merkittävästi NOx-päästöjä.

Realizing the Commercial Potential of Hierarchical Zeolites: New Opportunities in Catalytic Cracking

Many approaches to mesoporous zeolites have been reported. The preparation of mesoporous zeolite Y, as the most widely used zeolite in catalysis, its properties, and its application in fluid catalytic cracking (FCC) and hydrocracking are reviewed. Finally, the scale-up and use of mesostrutured zeolite Y on an industrial scale are described, as the first commercial application of hierarchical zeolites.

Efeito da incorporação de resíduos da indústria petrolífera na durabilidade de argamassas de reparação de estruturas de betão

Na presente dissertação, o trabalho desenvolvido teve como objetivo, a avaliação de alguns parâmetros de durabilidade de argamassas com incorporação de catalisador exausto de FCC (do inglês “Fluid Catalytic Cracking”) para serem utilizadas na reparação de estruturas de betão. O catalisador exausto de FCC é um resíduo da indústria petrolífera e o utilizado neste estudo é proveniente da refinaria da Petrogal, S.A. em Sines. A presente investigação baseou-se na preparação, e avaliação de propriedades, de duas séries distintas de argamassas: a série que se denominou “RAS” e a série que se denominou “Durabilidade”, nas quais se substituiu, parcialmente entre 5, 10 e 15%, em massa de cimento por resíduo exausto de FCC. As argamassas de ambas as séries diferenciam-se entre si, sobretudo, pela utilização de areia reativa nas argamassas da série RAS e de areia inerte no caso das argamassas da série durabilidade. Nas argamassas estudadas foram realizados ensaios no estado fresco e ensaios no estado endurecido. Os ensaios no estado fresco incluíram a determinação da consistência por espalhamento, da massa volúmica e do teor de ar. Nos ensaios no estado endurecido foram avaliadas, no caso das argamassas da série RAS a extensão da reação àlcalis-sílica e no caso das argamassas da série Durabilidade as resistências mecânicas - à flexão e à compressão, a resistência à carbonatação acelerada, o módulo de elasticidade à compressão, a absorção capilar, a permeabilidade ao oxigénio, a difusão de cloretos em regime não estacionário. O trabalho desenvolvido nesta dissertação demonstrou que a incorporação de catalisador exausto de FCC, em argamassas à base de cimento, minimiza o efeito de expansão das reações álcalis-sílica, bem como contribui para reduzir a absorção capilar e coeficiente de difusão de cloretos. No entanto, este resíduo quando incorporados em argamassas contribui para a diminuição da resistência à carbonatação acelerada e para o aumento da permeabilidade ao oxigénio.

ECO-betão com adição de resíduo da indústria petrolífera

Dissertação de natureza Científica para obtenção do grau de Mestre em Engenharia Civil na Área de Especialização em Edificações

Incorporação de resíduo da indústria petrolífera em argamassas de cal hidráulica para a reabilitação de edifícios

Trabalho Final de Mestrado para obtenção do grau de Mestre em Engenharia Civil na Área de Especialização de Edificações

Fractional order modelling of zero length column desorption response for adsorbents with variable particle sizes

This manuscript analyses the data generated by a Zero Length Column (ZLC) diffusion experimental set-up, for 1,3 Di-isopropyl benzene in a 100% alumina matrix with variable particle size. The time evolution of the phenomena resembles those of fractional order systems, namely those with a fast initial transient followed by long and slow tails. The experimental measurements are best fitted with the Harris model revealing a power law behavior.

An SEM investigation of the pozzolanic activity of a waste catalyst oil refinery

The most active phase of the fluid catalytic cracking (FCC) catalyst, used in oil refinery, is zeolite-Y which is an aluminosilicate with a high internal and external surface area responsible for its high reactivity. Waste FCC catalyst is potentially able to be reused in cement-based materials - as an additive - undergoing a pozzolanic reaction with calcium hydroxide (Ca(OH)2) formed during cement hydration [1-3]. This reaction produces additional strength-providing reaction products i.e., calcium silicate hydrate (C-S-H) and hydrous calcium aluminates (C-A-H) which exact chemical formula and structure are still unknown. Partial replacement of cement by waste FCC catalyst has two key advantages: (1) lowering of cement production with the associated pollution reduction as this industry represents one of the largest sources of man-made CO2 emissions, and (2) improving the mechanical properties and durability of cement-based materials. Despite these advantages, there is a lack of fundamental knowledge on pozzolanic reaction mechanisms as well as spatial distribution of porosity and solid phases interactions at the microstructural level and consequently their relationship with macroscopical engineering properties of catalyst/cement blends. Within this scope, backscattered electron (BSE) images acquired in a scanning electron microscope (SEM) equipped with Energy-Dispersive Spectroscopy (EDS) and by X-ray diffraction were used to investigate chemical composition of hydration products and to analyse spatial information of the microstructure of waste FCC catalyst blended cement mortars. For this purpose mortars with different levels of cement substitution by waste catalyst as well as with different hydration ages, were prepared. The waste FCC catalyst used is produced by the Portuguese refinery company Petrogal S.A.

Pozzolanic activity of oil-refining catalyst: evaluation by electron and atomic microscopy

The reuse of waste fluid catalytic cracking (FCC) catalyst as partial surrogate for cement can reduce the environmental impact of both the oil-refinery and cement production industries [1,2]. FCC catalysts can be considered as pozzolanic materials since in the presence of water they tend to chemically react with calcium hydroxide to produce compounds possessing cementitious properties [3,4]. In addition, partial replacement of cement with FCC catalysts can enhance the performance of pastes and mortars, namely by improving their compressive strength [5,6]. In the present work the reaction of waste FCC catalyst with Ca(OH)2 has been investigated after a curing time of 28 days by scanning electron microscopy (SEM) with electron backscattered signal (BSE) combined with X-ray energy dispersive spectroscopy (EDS) carried out with a JEOL JSM 7001F instrument operated at 15 kV coupled to an INCA pentaFetx3 Oxford spectrometer. The polished cross-sections of FCC particles embedded in resin have also been evaluated by atomic force microscopy (AFM) in contact mode (CM) using a NanoSurf EasyScan 2 instrument. The SEM/EDS results revealed that an inward migration of Ca occurred during the reaction. A weaker outward migration of Si and Al was also apparent (Fig. 1). The migration of Ca was not homogeneous and tended to follow high-diffusivity paths within the porous waste FCC catalyst particles. The present study suggests that the porosity of waste FCC catalysts is key for the migration/reaction of Ca from the surrounding matrix, playing an important role in the pozzolanic activity of the system. The topography images and surface roughness parameters obtained by atomic force microscopy can be used to infer the local porosity in waste FCC catalyst particles (Fig. 2).

Ilmaan johdettavien epäpuhtauksien päästökartoitus Porvoon öljynjalostamolla

Työn tarkoituksena oli laatia suunnitelma ilmaan johdettavien epäpuhtauksien päästökartoitukselle Porvoon öljynjalostamolla. Raskasmetallien, metaanin, fluorivetyhapon, rikkivedyn ja ammoniakin merkittävät päästöpaikat ja -tarkkailumenetelmät kartoitettaisiin tulevaa päästöraportointia varten. Tarkkailun alaisten komponenttien muodostuminen, kulkeutuminen ja merkittävät päästöpaikat Porvoon jalostamolla selvitettiin kirjallisuuslähteiden, jalostamon toimintajärjestelmän ohjeiden sekä työntekijöiden haastattelujen perusteella. Merkittäviä häiriöpäästötilanteita kartoitettiin ja arvioitiin jalostamon poikkeamatilastojen ja haastattelujen avulla. Normaalitoiminnan aikana tarkkailun alaisista epäpuhtauksista vapautuu ilmaan merkittäviä määriä ainoastaan metaania ja raskasmetalleja. Metaania vapautuu ilmaan polttoprosesseissa sekä hajapäästönä. Raskasmetallipäästöjä syntyy pohjaöljyn poltossa energialaitoksella sekä leijukatalyyttisessä krakkauksessa. Rikkilaitosten häiriötilanteista aiheutuu rikkivety- ja ammoniakkipäästöjä pääasiassa soihtujärjestelmän kautta. Alkylointiyksikön vuodoissa voi vapautua fluorivetyhappoa ilmaan. Päästömääriä arvioidaan pääosin laskennallisesti. Päästökartoitussuunnitelma on kokonaisuudessaan tämän työn liitteenä. Näyttäisi siltä, että TRS-yhdisteiden, ammoniakin ja fluorivetyhapon ilmapäästöt eivät ole merkittäviä Porvoon öljynjalostamolla. Uuden pohjaöljy-yksikön käyttöönotto on vähentänyt myös raskasmetallipäästöjä energialaitoksella. Metaanipäästö vaikuttaa kartoitukseen sisällytettävistä epäpuhtauksista merkityksellisimmältä Porvoon öljynjalostamolla.