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Spent FCC E-Cat: Towards a Circular Approach in the Oil Refining Industry

Author

Listed:
  • Francesco Ferella

    (Department of Industrial Engineering, Information and Economics, University of L’Aquila, Via G. Gronchi 18, 67100 L’Aquila, Italy)

  • Idiano D’Adamo

    (Department of Industrial Engineering, Information and Economics, University of L’Aquila, Via G. Gronchi 18, 67100 L’Aquila, Italy)

  • Simona Leone

    (Department of Industrial Engineering, Information and Economics, University of L’Aquila, Via G. Gronchi 18, 67100 L’Aquila, Italy)

  • Valentina Innocenzi

    (Department of Industrial Engineering, Information and Economics, University of L’Aquila, Via G. Gronchi 18, 67100 L’Aquila, Italy)

  • Ida De Michelis

    (Department of Industrial Engineering, Information and Economics, University of L’Aquila, Via G. Gronchi 18, 67100 L’Aquila, Italy)

  • Francesco Vegliò

    (Department of Industrial Engineering, Information and Economics, University of L’Aquila, Via G. Gronchi 18, 67100 L’Aquila, Italy)

Abstract

Every year the oil refining industry consumes thousand tons of fluid catalytic cracking zeolite from the E-cat generated in the fluid catalytic cracking (FCC) unit. In the present paper, a new process for recycling of fluid catalytic cracking catalysts (FCCCs) is presented. The process, previously tested at laboratory scale, was simulated by SuperPro Designer catalysts (FCCCs, also known as equilibrium catalysts, E-cat), which are mainly landfilled. Their intrinsic value is quite low and the content of rare earth elements (REEs), as lanthanum and cerium oxides, is around 3%wt. Moreover, their reuse in other industrial processes as raw material is very scarce. For each metric ton of spent FCCC treated for recovery of REEs, nearly the same amount of waste is generated from the process, the majority of which is represented by the solid residue resulting from the leaching stage. The manuscript presents a technological study and an economic analysis for the recovery of REEs, as well as the production of synthetic © software package. The plant was designed for a capacity of 4000 metric tons per year. The discounted cash flow (DCF) method was applied and Net Present Value (NPV) equal to about two-million € and Discounted Payback Time (DPBT) equal to two years defined the profitability of the process for recycling of FCCCs. This result depends on the selling price of zeolite. Consequently, a break-even point (BEP) analysis was conducted on this critical variable and the condition of economic feasibility was verified with a price of 1070 €/ton. This study tried to implement recycling strategies towards circular economy models.

Suggested Citation

  • Francesco Ferella & Idiano D’Adamo & Simona Leone & Valentina Innocenzi & Ida De Michelis & Francesco Vegliò, 2018. "Spent FCC E-Cat: Towards a Circular Approach in the Oil Refining Industry," Sustainability, MDPI, vol. 11(1), pages 1-19, December.
    • Handle: RePEc:gam:jsusta:v:11:y:2018:i:1:p:113-:d:193245
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    References listed on IDEAS

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    1. Idiano D’Adamo & Paolo Rosa & Sergio Terzi, 2016. "Challenges in Waste Electrical and Electronic Equipment Management: A Profitability Assessment in Three European Countries," Sustainability, MDPI, vol. 8(7), pages 1-19, July.
    2. Xibo Wang & Mingtao Yao & Jiashuo Li & Kexue Zhang & He Zhu & Minsi Zheng, 2017. "China’s Rare Earths Production Forecasting and Sustainable Development Policy Implications," Sustainability, MDPI, vol. 9(6), pages 1-14, June.
    3. Xuedong Liang & Meng Ye & Li Yang & Wanbing Fu & Zhi Li, 2018. "Evaluation and Policy Research on the Sustainable Development of China’s Rare Earth Resources," Sustainability, MDPI, vol. 10(10), pages 1-16, October.
    4. Carla Costa & José Carlos Marques, 2018. "Feasibility of Eco-Friendly Binary and Ternary Blended Binders Made of Fly-Ash and Oil-Refinery Spent Catalyst in Ready-Mixed Concrete Production," Sustainability, MDPI, vol. 10(9), pages 1-19, September.
    5. Isabel Banos-Gonzalez & Julia Martínez-Fernández & Miguel-Ángel Esteve-Selma & Patricia Esteve-Guirao, 2018. "Sensitivity Analysis in Socio-Ecological Models as a Tool in Environmental Policy for Sustainability," Sustainability, MDPI, vol. 10(8), pages 1-30, August.
    6. Abd El-Azeem Sallam & Mateb S. Al-Zahrani & Mohammad I. Al-Wabel & Abdullah S. Al-Farraj & Adel R. A. Usman, 2017. "Removal of Cr(VI) and Toxic Ions from Aqueous Solutions and Tannery Wastewater Using Polymer-Clay Composites," Sustainability, MDPI, vol. 9(11), pages 1-14, October.
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    Cited by:

    1. Fernando E. García-Muiña & María Sonia Medina-Salgado & Anna Maria Ferrari & Marco Cucchi, 2020. "Sustainability Transition in Industry 4.0 and Smart Manufacturing with the Triple-Layered Business Model Canvas," Sustainability, MDPI, vol. 12(6), pages 1-19, March.
    2. Amato, A. & Becci, A. & Birloaga, I. & De Michelis, I. & Ferella, F. & Innocenzi, V. & Ippolito, N.M. & Pillar Jimenez Gomez, C. & Vegliò, F. & Beolchini, F., 2019. "Sustainability analysis of innovative technologies for the rare earth elements recovery," Renewable and Sustainable Energy Reviews, Elsevier, vol. 106(C), pages 41-53.

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