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REFINERY CATALYST

SOLUTIONS

NEBULA® catalysts
Economic benefits from unmatched catalyst activity
NEBULA catalyst technology has demonstrated near continu- NEBULA’s high activity for hydrodesulfurization (HDS), hydrode-
ous growth in the volume and number of its applications (Figure nitrogenation (HDN) and hydrogenation drives the efficient use
1). The key to its success is the economic value it brings to units of existing assets by pushing their limits. Most NEBULA applica-
that need its high activity. Albemarle continues to develop the tions are initiated by asking “what if?” When the only constraint
NEBULA technology platform to open up more opportunities. to answering that question in the affirmative is catalyst activity,
Remarkably, nearly 80% of all the units that have tried NEBULA NEBULA is a potential champion.
are still using it: nearly 40% of them in multiple cycles.
NEBULA is used in applications ranging from refining to petro-
Since the initial applications of NEBULA technology, significant chemicals, but mostly for fuels: treating distillate to a very low
advances have been made to its product and on how it is best sulfur and/or aromatics content, and pretreatment of feedstocks
applied. This has expanded the application range and improved for hydrocracking.
the economic returns. The improvements made to the NEBULA
platform include Distillate hydrotreating
ƒƒ lower bulk density The application of NEBULA in distillate hydrotreaters is typically
ƒƒ increased strength in units with >50-bar hydrogen partial pressure. Depending on
ƒƒ larger pores for heavier feeds the position of NEBULA in the reactor, a wide variety of targets
is achievable. Several commercial operations have conventional
ƒƒ higher activity NiMo catalyst at the top of the reactor, NEBULA in the middle sec-
ƒƒ STAX® catalyst system design. tion and a CoMo catalyst at the bottom. This approach exploits
NEBULA’s high HDN and HDS activity while avoiding a commen-
The higher cost of NEBULA catalysts compared with conventional
surate increase in hydrogen consumption.
catalysts is offset by economic returns that may be difficult to ac-
complish otherwise. Generally, the economic return is generated This positioning prevents excess hydrogenation of monoaromat-
through one of the following: ics, which NEBULA might induce in a low-nitrogen environment,
but it can be reversed when hydrogen consumption is desirable
ƒƒ increased throughput at constant cycle
(density reduction, cetane uplift or aromatics reduction). For such
ƒƒ distressed feed processing at constant cycle a case, a catalyst system with NiMo catalyst at the top and middle
ƒƒ capital avoidance of the reactor, and NEBULA at the bottom places NEBULA in a
ƒƒ higher value product low-nitrogen environment where it can substantially increase the
ƒƒ increased volume by hydrogen addition. saturation of monoaromatics.

60 40
Condition 1 Condition 2 Activity return
35
50
30
Product sulfur (ppm)

NEBULA-STAX
Number of cycles

40 Total NEBULA cycles Conventional
25
Cycles of current users
20
30
30% LCO added 60% LCO added
15
20 10

10 5
0
0 15 20 25 30 35 40 45 50 55
2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 Days onstream

Figure 1: NEBULA applications are growing and user satisfaction Figure 2: The effect of cracked feedstocks on NEBULA–STAX and
is high. conventional catalyst systems

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An example of the capabilities of NEBULA–STAX loadings is 25
shown in Figure 2. In this pilot plant test, the response of a
conventional and of a NEBULA–STAX catalyst system to increased

Temperature from Base (oC)
20
cracked feed addition were evaluated. It can easily be seen
that the system containing NEBULA has substantially improved 15
performance in all cases, but, most importantly, it can produce
ultra-low-sulfur diesel (ULSD) in situations where the conven- 10
tional catalyst could not. This benefit is consistently maintained,
even with the activity return point condition at the end of the 5
test, which clearly demonstrates NEBULA’s stability.
0
Hydrocracking pretreatment 0 100 200 300 400 500 600 700 800 900
Days onstream
For hydrocracking pretreatment, the main goal is maximum HDN
Figure 3: A NEBULA–STAX system demonstrates outstanding
activity, and NEBULA is ideal for this. It is possible to exploit NEB-
stability.
ULA’s HDN activity for economic return in several ways. NEBULA
could be used to maintain the same performance as conventional
catalyst while increasing throughput or to increase cycle length
at same throughput. However, as most refineries already run at Commercial experience
maximum throughput and have turnaround constraints, there are Commercial experiences confirm the benefits of NEBULA–STAX
better ways to exploit NEBULA’s activity. systems. After a first fill, NEBULA is often used for subsequent
reactor loadings because it delivers significant economic returns.
Operating the pretreatment reactor for lower nitrogen slip to the
downstream cracking catalyst improves conversion through re- The superior activity of NEBULA opens up many opportunities to
duced inhibition of the cracking sites. One way to use the lower capture economic return. In combination with Albemarle’s STAX
nitrogen slip is to increase the overall conversion using the same technology, it is possible to obtain a significant performance
cracking catalyst and volume. Another option is to change the enhancement with a relatively small NEBULA content, which re-
yield structure towards more distillate by using a more distillate- duces catalyst system expenditure and often reduces the payback
selective catalyst at constant conversion. Yet another opportu- time for the NEBULA investment to a few months.
nity is to change the feed diet to include distressed, lower-cost Could you get better return on your hydrotreating assets with
components and capture the increased cracking margin while higher catalyst activity? If so, NEBULA may be the answer.
maintaining throughput and cycle length.
Albemarle has much commercial experience with NEBULA in
hydrocracking pretreatment operations. One notable case is a
150-bar mild hydrocracker where, through the use of NEBULA,
it was possible to reduce the start-of-run weighted average
bed temperature by 20°C (Figure 3). This enabled the refiner to
practically double the cycle length. As with ULSD applications, a
STAX catalyst system design is always used. In a hydrocracker, this
strategy protects NEBULA from fouling materials in the feed and
tunes the NEBULA intake to control heat release and deliver the
highest activity per volume to the refiner.
In addition to VGO hydrocracking pretreatment service, NEBULA
has been widely applied in LCO hydrocracking pretreatment
units.

For more information on this or other Albemarle products and technologies, please contact your Albemarle representative.

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