Membrane Solution for Enhancing the Value of FCC Slurry Oil

Jan 02, 2025

Fluid Catalytic Cracking (FCC) is a secondary conversion process used in the petroleum refining industry to convert heavy fractions of petroleum into valuable fuels such as gasoline, diesel, and LPG. In the process of heavy oil fluid catalytic cracking, the formation of FCC slurry oil is unavoidable. FCC slurry has high density, high molecular weight, high viscosity, low hydrogen-to-carbon atom ratio, high aromatic content, and a significant amount of catalyst particles.

FCC slurry oil has a high content of heavy aromatics, low impurities, and is almost entirely composed of short-side-chain aromatic compounds. This makes it an excellent feedstock for the production of needle coke, carbon black, and softeners for the rubber industry, as well as a hydrogenation raw material.
This slurry not only serves as a new source of energy but is also rich in valuable chemical feedstocks like polycyclic aromatic hydrocarbons.
The high concentration of catalyst dust in the FCC slurry oil (typically between 3000 and 6000 μg/g, with a particle size of approximately 0.80μm) significantly complicates its comprehensive utilization.
However, the aforementioned processes have stringent requirements for the solid content in the oil slurry. For needle coke production, the solid mass fraction of the raw material must be ≤100 μg/g. For carbon black production, the solid mass fraction must be ≤500 μg/g. For rubber softener production, the solid mass fraction should be <500 μg/g, and for hydrogenation feedstock, the solid mass fraction should be <20 μg/g.
Therefore, selecting appropriate separation technologies is crucial for the efficient separation and purification of FCC slurry oil.
Challenges of Traditional Filtration Methods
Currently, the separation of catalysts from FCC slurry oil primarily relies on stainless steel wire mesh filters. While this method is relatively common in industrial applications, it suffers from low filtration precision, often leaving catalyst residue in the treated slurry at several hundred μg/g. Furthermore, filter blockage is a significant issue, occurring within one to two hours of operation, necessitating frequent cleaning and replacement by operators, which in turn reduces production efficiency and increases costs.
Features of Ceramic Membranes

Nano-level filtration with high precision
High temperature resistance and wear resistance
Low failure rate and high reliability
Uniform pore size, resistant to clogging
Easy to clean with excellent regeneration performance
Crossflow without cake formation

SEM Image of Ceramic Membrane
Process Advantages of Ceramic Membranes
In contrast to traditional filtration methods, ceramic membrane technology offers a more efficient and environmentally friendly solution.
>>Ceramic membranes exhibit excellent high-temperature resistance, allowing them to operate stably in harsh industrial environments.
>>Ceramic membrane has a high filtration precision, enabling the solid content of purified slurry oil to be reduced to ≤50 ppm, thereby significantly lowering the residual catalyst levels.
>>Ceramic membranes demonstrate superior regeneration capabilities compared to metal filters, effectively reducing operational costs and enhancing actual production efficiency.
>>In practical applications, treatment of FCC slurry oil with Ceramic Membranes can achieve a purification yield of over 90%, providing an ideal feedstock for blending low-sulfur marine fuel oil.
>>Ceramic membrane not only meets modern environmental requirements but also enhances the overall economic value of FCC slurry oil, promoting sustainable development within the industry.
Through continuous technological innovation and efficiency improvement, FCC slurry oil will play an increasingly pivotal role on the path toward green chemistry, enabling efficient resource utilization and sustainable environmental practices to support the global energy transition.

Membrane System onsite

Ceramic Membranes present an innovative solution to the limitations of traditional filtration technologies for FCC slurry oil. With their advantages in efficiency, environmental sustainability, and cost-effectiveness, they open new avenues for the high-value utilization of FCC slurry oil. This advancement signifies not just a breakthrough in technology, but also a model for achieving a win-win situation between environmental responsibility and economic gain, contributing new strength to the sustainable development of the chemical industry.

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