Fluid catalytic cracking (FCC) is a key process in modern petroleum refining for converting heavy vacuum distillates and residual oils into valuable light products such as gasoline, diesel, and petrochemical olefin fractions. In the FCC process, long-chain hydrocarbons are contacted with a fluidized solid catalyst in a riser reactor at temperatures of approximately 480–550 °C and moderate pressures of about 1.5–3 bar, where C–C bonds are selectively cracked to produce lighter hydrocarbons.
The FCC process comprises feed pretreatment, catalytic cracking, continuous catalyst regeneration, and fractionation of the product vapors. Zeolite-based catalyst systems, primarily stabilized forms of zeolite Y embedded in oxide matrices, are widely applied due to their high acidity, excellent thermal and hydrothermal stability, and optimized particle properties. These characteristics enable high conversion efficiency and favorable product selectivity, particularly toward high-octane gasoline and propylene.
FCC units offer refineries high feedstock flexibility, efficient energy utilization, and the ability to adapt to changing market demands. The selection of suitable zeolite and adsorbent grades for feed pretreatment and gas treatment contributes significantly to process stability, protection of sensitive equipment, and extended catalyst and unit run lengths.
