fluid catalytic cracking

Fluid catalytic cracking (FCC) is a crucial chemical process in petroleum refining that converts heavy hydrocarbon fractions into more valuable lighter products, primarily gasoline. This process, commercialized in 1942, significantly increased the yield of high-octane gasoline to meet rising demand.1

FCC utilizes a finely divided solid catalyst, often zeolitic, which behaves like a liquid when agitated. The process involves vaporizing oil feed and mixing it with hot catalyst in a riser reactor. Here, long-chain hydrocarbons are broken down into smaller molecules through a mechanism involving carbonium ions.1

The catalyst, after reacting, is continuously regenerated by burning off deposited carbon. Modern FCC units operate at high temperatures (480–550 °C) and relatively low pressures. This technology represents a breakthrough in catalyst development and is foundational to modern petroleum refining.1