This review looks at the main processes available for the production of light olefins with a focus on maximizing the production of propylene. Maximization of propylene production has become the focus of most refineries because it is in high demand and there is a supply shortage from modern steam crackers, which now produce relatively less propylene. The flexibility of the fluid catalytic cracking (FCC) to various reaction conditions makes it possible as one of the means to close the gap between supply and demand. The appropriate modification of the FCC process is accomplished by the synergistic integration of the catalyst, temperature, reaction-residence time, coke make, and hydrocarbon partial pressure. The main constraints for maximum propylene yield are based on having a suitable catalyst, suitable reactor configuration and reaction conditions.

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The catalytic cracking of naphtha fractions for propylene production was investigated under high severity catalytic cracking conditions (high temperatures and high catalyst to oil ratio). Straight run naphtha and cracked naphtha along with a with proprietary catalyst were used, and reaction was carried out using a catalyst to oil ratio (C/ O) of 3-6 at 600-650°C and 1 atm in a micro activity testing (MAT) unit. The results from this experiments show that light cracked naphtha (LCN) gave the highest propylene yield of 18% at 650°C, and that propylene yield depends on the naphtha fraction being used as feed. The trend for reactivity and propylene yield was as follows: light cracked naphtha [ heavy straight run naphtha [ light straight run naphtha [ heavy cracked naphtha.

Catalytic conversion of heavy naphtha to reformate product over the phosphorus-ZSM-5 catalyst at a lower reforming temperature.