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ISSUE 84 SPRING 2015

ALBEMARLE’S NEW STRUCTURE TO BOOST GROWTH


AND PERFORMANCE
NEW FCC-PT CATALYSTS PROVIDE MORE FLEXIBILITY
TO MEET VARYING DEMANDS
HOW ALBEMARLE’S NEW FCC PROCESS SIMULATOR
PROVIDES REFINERS WITH ACTIONABLE ADVICE

ALBEMARLE CATALYST COURIER ISSUE 84 1


www.albemarle.com

INSIDE THIS ISSUE…


4 NEWS FROM ALBEMARLE
6 CLEAN FUELS TECHNOLOGIES: OPPORTUNITY KNOCKS
8 ACTION™ FCC CATALYST SIGNIFICANTLY IMPROVES REFINER’S PROFITABILITY
10 IMPROVING FCC CATALYST SELECTION BY ADJUSTING LABORATORY DATA
13 MAKE THE BEST DECISIONS ABOUT CATALYST TESTING
16 DEVISING THE BEST FCC SOLUTIONS
18 COMBUSTION PROMOTERS ON CALL
20 REACHING FOR THE STARS
22 FLEXIBILITY FOR FCC PRETREATMENT
25 ALBEMARLE’S FCC PRETREATMENT (FCC-PT) SOLUTIONS FOR CUSTOMERS’ CHALLENGES

EVENTS DIARY 2015 Managing editor


Chris Dean
E: chris.dean@albemarle.com
June
Correspondence and distribution for Catalyst Courier
9–11 12th Annual Global Petrochemicals Conference, Dusseldorf, Chris Dean
Germany Albemarle Corporation
Baton Rouge Tower, 451 Florida Street
14–19 NAM24 Pittsburgh, PA, USA Baton Rouge, Louisiana 70801, USA
www.albemarle.com
E: catmaster@albemarle.com
October
4–7 AFPM Q&A and Technology Forum, New Orleans, LA, USA For North and South America, contact:
Albemarle Corporation
28–29 Asian Downstream Week, Singapore T: +1 281 480 4747
E: catmaster@albemarle.com
November For Europe, the Middle East, CIS and the Indian subcontinent, contact:
17–19 ERTC 20th Annual Meeting, Rome, Italy Albemarle BV
T: +31 20 6347300
E: catmaster@albemarle.com
December
For Asia Pacific, contact:
7–9 North Africa Downstream Summit, Cairo, Egypt Albemarle Chemicals (Shanghai) Co., Ltd
9–10 Bottom of the Barrel Technology Conference, Abu Dhabi, UAE T: +86 21 6103 8666
E: catmaster@albemarle.com

The information presented herein is believed to be accurate and reliable but


is presented without guarantee or responsibility on the part of Albemarle
Corporation and its subsidiaries. It is the responsibility of the user to comply with
all applicable laws and regulations and to provide for a safe workplace. The user
should consider any health or safety hazards or other information contained
herein only as a guide, and should take those precautions which are necessary or
prudent to instruct employees and to develop work practice procedures in order
to promote a safe work environment. Further, nothing contained herein shall be
taken as an inducement or recommendation to manufacture or use any of the
herein materials or processes in violation of existing or future patent. No part of
this publication may be reproduced, stored in a retrieval system or transmitted
in any form or any means, electronic, mechanical, photocopying, recording or
otherwise, without the prior permission of the copyright owner.

Copyright Albemarle Corporation, 2015

2 ALBEMARLE CATALYST COURIER ISSUE 84


SILVIO GHYOOT
PRESIDENT, REFINING SOLUTIONS

In times of market volatility, companies need a more focused approach. Recognizing


this, we have realigned our businesses and strategic assets to help accelerate
growth, boost performance levels and create greater synergies. For example, our
reorganization of Refining Solutions, which now consists of the Heavy Oil Upgrading
and Clean Fuels Technologies businesses, will enable us to deliver a robust portfolio of
catalyst solutions across the entire refinery process.

Volatility is just one of the factors that the industry is currently facing. In this issue of
Catalyst Courier, we examine this and a range of other business and technical themes.

Our first article (page 6) focuses on clean fuels technology and the industry’s response
to market changes such as growing demand for transportation fuels and ever-tighter
fuel standards that have contributed to expansion of the global hydroprocessing
catalyst market.

We consider the shift in refinery economics and operating objectives that have
resulted from North America’s tight oil revolution: the decrease in gasoline demand,
new Renewable Fuel Standard requirements and the USA’s new position as an
exporter of refining products (page 8).

We also look at the limitations of laboratory testing for refinery catalysts with a low
zeolite to matrix (Z/M) ratio (page 10). This shows how carefully conducted back-to-
back tests with low(er) Z/M ratio catalysts can overcome coke artifacts and establish
their true performance, thereby enabling refiners to increase cracking margins.

Our penultimate article (page 22) highlights the importance of flexibility for refiners
that need to produce ultra-low-sulfur gasoline and increase diesel fuel output. To
achieve this FCC pretreatment units need robust and reliable catalyst systems that
provide high activity and good stability. We look at four new catalysts that offer
flexibility against varying commercial demands and feedstock compositions.

Across the industry, operators are facing commercial headwinds, but Albemarle is
responding strongly to these challenges. We are also looking to a more positive future
as we explore plans for expansion in the Middle East.

Whatever the future holds, Albemarle is ready to help its customers transform
challenges into opportunities.

ALBEMARLE CATALYST COURIER ISSUE 84 3


NEWS
FROM ALBEMARLE

ORGANIZATIONAL REALIGNMENT ALBEMARLE


TO BOOST GROWTH AND AND ASOS
PERFORMANCE COLLABORATE
ON NEW FCC
CATALYST
Albemarle has realigned its global and Clean Fuels Technologies
businesses and strategic assets into businesses, and will deliver a
a more market-focused structure robust portfolio of catalyst
in a bid to speed up growth, boost
performance levels and create
solutions that apply to the entire
refinery process. Performance
FACILITY
greater synergies throughout the Chemicals will combine the
corporation. lithium, aluminum alkyls and Albemarle Corporation has entered
derivative catalysts businesses into discussions with Middle Eastern
The new structure consists of three with the existing Performance partner Ali & Sons Oilfield Supplies &
global business units: Chemetall Chemicals unit. Services LLC (ASOS) on constructing a
Surface Treatment, Refining manufacturing facility for FCC catalysts
Solutions, and Performance Albemarle has put a senior and additives in Abu Dhabi, UAE.
Chemicals. Chemetall will continue leadership team in place to head
to supply specialty chemicals the new departments, which Abu Dhabi is the ideal site for
with a focus on processes for the will report directly to President the proposed facility because it
surface treatment of metals and and Chief Executive Officer Luke would enable Albemarle to meet
plastics. Refining Solutions consists Kissam. The restructuring became rapidly growing regional demand
of the Heavy Oil Upgrading effective at the end of Q1 2015. for refinery catalyst solutions and
provide unmatched security of supply
for its customers in the Middle East.

The proposed facility would


manufacture Albemarle’s value-
adding AFX® catalysts, which
promote increased propylene yield
from resid feedstocks.

The plans for the project follow


Albemarle’s successful delivery of
catalysts for the startup of the FCC
unit in Takreer’s newly expanded
Ruwais refinery in Abu Dhabi.

ABU DHABI IS THE IDEAL


SITE FOR THE PROPOSED
FACILITY BECAUSE
IT WOULD ENABLE
ALBEMARLE TO MEET
RAPIDLY GROWING
REGIONAL DEMAND
FOR REFINERY CATALYST
SOLUTIONS.

4 ALBEMARLE CATALYST COURIER ISSUE 84


NICHE CATALYST TO JOIN THE STARS HYDROPROCESSING
Albemarle is gearing up to launch
ALLY UOP HITS A
pretreatment feed to boost overall
the latest, leading-edge addition
CENTURY
to its high-activity STARS® catalyst
hydrocracking conversion and
performance,” said Edwin Berends,
lineup. The catalyst, Ketjenfine ® vice president of Albemarle’s
(KF) 870, which is going through Refining Solutions Research and
the final stages of pilot plant Technology group.
testing, is expected to address a
niche in medium-to-high-pressure This new STARS technology has
hydrocracking pretreatment been developed by Albemarle and
operations. Nippon Ketjen, and should be rolled
out worldwide during the second UOP LLC, one half of a hydroprocessing
“Extensive testing has shown half of this year. The catalyst will be partnership with Albemarle, has
that this catalyst is setting new available through Albemarle, Nippon celebrated its 100-year anniversary.
benchmarks in reducing the Ketjen and the UOP–Albemarle
nitrogen content in hydrocracking Hydroprocessing Alliance. UOP, a Honeywell company, was
established to commercialize the first
conversion technology for upgrading
crude oil. It managed to increase
the amount of gasoline that could
ALBEMARLE AND be derived from crude oil fourfold,
thereby creating the foundations

UTRECHT UNIVERSITY for modern oil refining. Today, a


century later, 31 of the 36 refining

STRENGTHEN technologies applied worldwide use


UOP’s products.

PARTNERSHIP In 2006, Albemarle and UOP


joined forces to create the
Hydroprocessing Alliance, which
EELCO VOGT has since supplied technology
and catalysts to about half
Dr Eelco Vogt, Albemarle’s research “Dr Vogt will be a valuable the world’s hydroprocessing
and development adviser, has projects. The Alliance combines
asset to the university’s
become a professor of refinery the strengths of UOP as a leading
catalysis research program.” developer of hydrotreating and
catalysis at Utrecht University, the
Netherlands. Vogt will research hydrocracking process technology
“Albemarle has been fostering
techniques for improving the and hydrocracking catalysts, and
a collaborative partnership
sustainability of refinery processes Albemarle as a leading developer
with the catalysis researchers
through the development of and supplier of innovative refinery
at Utrecht University for several
advanced catalysts. hydrotreating catalysts and
years,” added Edwin Berends, vice
solutions.
president of Albemarle’s Catalyst
“The appointment of Dr Vogt is part Solutions Research and Technology
of Utrecht University’s strategic “Albemarle congratulates UOP on
group. “With this new chair
theme for promoting sustainability a successful 100 years in business
appointment, we hope to increase
in the broad area of energy and looks forward to continuing
our fundamental understanding
conversion, including the oil refining of catalysis so that we can develop to jointly build an even stronger
industry,” said Professor Bert technology leadership in the coming
better technologies that will
Weckhuysen, Utrecht University. years through the UOP–Albemarle
promote more sustainable use of
Hydroprocessing Alliance,” says
scarce resources.”
Edwin van Rooijen, alliance director,
clean fuel technologies, Albemarle.

ALBEMARLE CATALYST COURIER ISSUE 84 5


SPECIAL FEATURE

CLEAN FUELS TECHNOLOGIES:


OPPORTUNITY KNOCKS
Albemarle is ready to take advantage of anticipated CARL VAN DER GRIFT
VICE PRESIDENT, CLEAN
market changes. FUELS TECHNOLOGIES

With its diverse portfolio Market reports forecast that global


demand for transportation fuel will
The implementation of Tier 3 gasoline
in the USA will drive demand for FCC
of catalyst solutions, continue to grow by between 1 and pretreatment catalysts showing a
2% annually. However, this growth is higher hydrodesulfurization activity
Albemarle is poised not uniform; it is fastest in developing to enable deeper desulfurization
to take advantage of economies such as Asia and India. As before the FCC unit or increased
refiners are continuously investing hydrodesulfurization of FCC gasoline
the growing global to extract more clean transportation by post-treatment. Similarly, the
hydroprocessing catalyst fuels from every barrel of crude and
demand is shifting to the developing
introduction of the China V diesel
specification by the end of 2016
market, which is being regions, Albemarle’s Clean Fuel will increase the demand for
Technologies (CFT) business is well- ultra-low-sulfur-diesel catalysts
driven by steady growth in positioned to manage the upcoming and hydrocracking catalysts in
demand for transportation opportunities. China. Finally, the introduction of
tighter marine fuel specifications
fuels and increasingly Similarly, clean air mandates are (MARPOL convention) around the
stringent fuel standards. driving above baseline growth world will drive demand for deeper
for hydrotreating catalysts in the desulphurization of bunker fuels.
CFT business. The next decade
will see increasingly stringent fuel Consequently, demand from refiners
specifications for sulfur worldwide. for Albemarle CFT catalysts continues
Although the greatest impact from to be very strong. The company
tightening standards will be driven believes that its business growth will
by lower sulfur limits in gasoline and keep pace with global hydroprocessing
ultra-low-sulfur diesel for light-duty catalyst demand. With its diverse
vehicles, marine fuel specifications and product portfolio and key international
commercial vehicle specifications will partnerships, e.g., with UOP,
also have meaningful impacts. Nippon Ketjen and Eurecat, it can
provide tailor-made solutions for all

6 ALBEMARLE CATALYST COURIER ISSUE 84


hydroprocessing operations.
Albemarle’s vast database of global
ALBEMARLE CONTINUES
Albemarle also sees growth potential
with tight oil in North America. The commercial experiences enables it to TO DEVELOP HIGH-
impurities in tight oil necessitate using share performance observations for QUALITY PRODUCTS
improved guard-bed catalysts to trap catalyst systems operating at various
the contaminants. Consequently, the conditions and processing different THAT CAN BE
company expects to see a shift in feedstocks around the world. This MANUFACTURED AT
demand from main-bed catalysts to application knowledge is very important
guard bed catalysts. The enhanced for advising refiners on how to optimize COMPETITIVE COSTS.
portfolio of Ketjenguard® catalysts their unit operations and unlock the total ITS PLANTS FOCUS
potential of their catalyst systems.
should help here. New grades are
available for removing arsenic, iron, and
ON HIGH OPERATING
silicon. These products are getting a Albemarle’s CFT business helps EQUIPMENT EFFICIENCY
refiners to get the most out of their
good reception, as they offer customers
longer catalyst cycles through better hydroprocessing assets in a responsible
AND CONTINUOUS
protection of the main-bed catalysts. way, not by taking chances but by PERFORMANCE
calculating the limits and operating
close to them for optimal results,
IMPROVEMENT.
High quality and know-how
regardless of the crude characteristics,
Albemarle continues to develop
the desired product slate or the
high-quality products that can be
operating conditions.
manufactured at competitive costs. Its
plants focus on high operating equipment
efficiency and continuous performance
improvement. The company fully utilizes
the collective knowledge of its application
technology experts and sales and
technical service teams as they deepen FOR MORE INFORMATION, CONTACT:
Carl van der Grift
their hydroprocessing know-how by Email: carl.van.der.grift@albemarle.com
working with customers.

ALBEMARLE CATALYST COURIER ISSUE 84 7


TECHNICAL FOCUS

ACTION™ FCC CATALYST SIGNIFICANTLY IMPROVES


REFINER’S PROFITABILITY
Boosting margins through improved selectivities

The tight oil revolution, the decrease LPG and C4 olefins yield profile needed carbon level typically of about 1.3
in gasoline demand, Renewable for maximum profitability. ACTION also but occasionally over 2.0. Sulfur is
Fuel Standard requirements and promotes isomerization reactions to generally about 0.5 wt%, and nickel
the USA becoming an exporter of improve octane. By utilizing the most and vanadium, at roughly equal
refining products have caused a shift accessible iron- and calcium-resistant amounts in the feed, combine to deposit
in refinery economics and operating matrix available, ACTION can withstand about 5000‑ppm total metals on the
objectives. Distillate and alky these metals while maintaining activity equilibrium catalyst. The daily catalyst
feedstock from the FCC unit are now and bottoms cracking. replacement rate is about 3.3% with
often more profitable than gasoline, ACTION, which resulted in a greater than
and cheaper domestic tight crude oils Resid feed application 50% catalyst changeover in three weeks.
have overtaken heavier and sourer A refiner operating an FCC unit that
crudes as the feedstocks of choice. processes a light, sweet atmospheric When the previous catalyst was being
resid feed has seen an estimated profit used, the riser temperature was
These sweet paraffinic crudes generate increase of over $1 per barrel of feed maintained at the maximum limit to
FCC feeds with lower distillate for the unit since switching to ACTION minimize bottoms yield. However, with
production, gasoline octane and C4 catalyst. The key economic drivers for the introduction of ACTION catalyst,
olefinicity. In addition, tight oil feeds are the change were minimizing slurry make bottoms cracking was improved, which
low in nickel and vanadium but high in and increasing C4 olefinicity to utilize meant the refiner could reduce the riser
iron, calcium and often sodium, which the available alkylation capacity. ACTION temperature by 15°F. This then enabled
create challenges for FCC catalysts. provided increased bottoms cracking into the refiner to tune the FCC unit to
LCO, greatly improved the LPG olefinicity optimal LCO and olefin yields.
To overcome these challenges, Albemarle and boosted the octane rating by almost
designed ACTION, a novel FCC catalyst one number at near constant gasoline ACTION has a lower zeolite activity and
that combines its renowned matrices, volume. All of these benefits resulted in a higher matrix activity than the refiner’s
novel high silica-to-alumina ratio zeolite a significant economic gain. original catalyst. However, when compared
technologies and a unique manufacturing on a constant operating conditions basis,
process. This catalyst enables an FCC unit The FCC unit is a large side-by-side unit both the catalysts yielded similar levels
operator to target the distillate, gasoline, and has a combined feed Conradson of conversion. This was in part because

Coke selectivity, wt%


Relative conversion, wt% (coke/kinetic conversion shown) LCO/bottoms, LPG olefinicities,
model corrected model corrected wt%/wt% model corrected wt%/wt% model corrected
8 8
3.0 3.0 4.0 4.0 0.85 0.85
6 6 C3 olefinicity
4 4 0.80 0.80

2 2 2.5 2.5 3.0 3.0 0.75 0.75


0 0
0.70 C4 olefinicity 0.70
-2 -2
2.0 2.0 2.0 2.0 0.65 0.65
-4 -4

-6 -6 0.60 0.60

-8 -8 1.5 1.5 1.0 1.0 0.55 0.55


Competitor ACTION Competitor ACTION Competitor ACTION Competitor ACTION

Figure 1: Compared on the basis of constant unit operating conditions Figure 2: ACTION’s high matrix activity converted more bottoms
and feed properties, both catalysts delivered the same unit conversion than the competitor’s catalyst at constant conversion; the ADZT-100
and coke selectivity. zeolite technology maximizes LPG olefinicity.

8 ALBEMARLE CATALYST COURIER ISSUE 84


ACTION catalyst additions were lowered ZSM-5 additive was employed with both How the data were analyzed
to maintain near constant equilibrium the competitive catalyst and with ACTION The data for process conditions, feed
catalyst activity. Figure 1 shows that high- to assist in maximizing LPG production. properties and product properties and
matrix catalysts do not show poorer coke However, the amount of additive in the yields were supplied by the refiner,
selectivity than low matrix catalysts in unit E-cat was slightly lower on average beginning with data taken about a
commercial applications, as is often seen during the ACTION period. year before the switch to ACTION
in small-scale laboratory testing.1 catalyst. For both the raw and model-
In a similar way to in other commercial corrected data in this comparison,
the competitor’s catalyst period and
The high matrix activity of ACTION provided experiences, ACTION also raised
ACTION period were 47 and 31
a significant advantage in terms of greater both RON and MON. In the raw data
individual weekly cases respectively. All
bottoms cracking. Figure 2 clearly shows corrected only to constant gasoline cut the data points in the ACTION dataset
a substantial increase in the LCO-to- point, ACTION improved both RON and are at 70% or greater turnover of
bottoms ratio at constant conversion for MON slightly, which becomes more ACTION into the inventory.
ACTION, which satisfied one of the primary impressive when considering the refinery
economic goals of the refiner. ran at a 15°F lower riser temperature To correct for changes in operations,
with ACTION. Forecasting to constant feed and product cut points,
With regard to maximizing alky operating conditions, ACTION boosted Albemarle employed an FCC
feed, ACTION also outperformed the both octane values by about one number. simulator model developed by KBC
competition. Although ACTION provided A widely known rule of thumb states that to forecast each mass-balanced case
a similar LPG make to the competitor’s ZSM-5 technology is known to increase back to a constant basis. This enabled
catalyst at equal conditions, Figure 2 MON at only 50% the rate of RON. Albemarle to forecast the data to
a consistent set of unit conditions,
shows that the LPG was considerably Figure 3 demonstrates the ADZT‑100
feed rate and properties, and E-cat
more olefinic, especially in C4 olefins. zeolite technology isomerization activity
properties, thereby removing the
This olefinicity improvement would be in ACTION helped boost MON by 90% of clouding effects of operational and
even greater if the data in Figure 2 were the increase seen in RON. feed changes from the analysis of
corrected to account for a ZSM-5 additive catalyst performance.
level equal to that used during the
competitive catalyst’s incumbency.

Reference
1
Pouwels, C. and Bruno, K.: “Better catalyst
Relative octanes Relative octanes evaluation strategies for maximizing FCCU
raw data model corrected margins”, paper AM-13-05 presented at
2 RON 2 RON the 2013 AFPM International Petrochemical
Conference, San Antonio, USA (March 24–26,
1 1 2013)

0 0

-1 -1 FOR MORE INFORMATION, CONTACT:


MON MON Alan Kramer
2 2 Email: alan.kramer@albemarle.com
George Yaluris
Email: george.yaluris@albemarle.com
1 1

Competitor ACTION Competitor ACTION

Figure 3: ACTION increases RON and MON at a lower riser temperature


when looking at the raw data and by about one number over the
competitor’s catalyst when corrected to constant conditions.

ALBEMARLE CATALYST COURIER ISSUE 84 9


TECHNICAL FOCUS

IMPROVING FCC CATALYST SELECTION BY


ADJUSTING LABORATORY DATA
Part 1: The need for and concepts behind coke correction methods

Nowadays, refining companies Albemarle works with customers coke selectivity delta observed for
apply different approaches around the world and has observed that legacy protocols contrasts dramatically
to selecting catalysts for their some have invested considerable time with that expected from commercial
FCC units with the objective of and effort in improving their catalyst FCC unit performance, as shown in the
improving performance and testing methods and become more second bar.
increasing their economic margins. sophisticated in the process. Those
The most common approaches improvements include, for example, The gap between laboratory and
are based on laboratory testing exploring and optimizing different commercial performance is a testing
or commercial side-by-side trials. deactivation protocols or different artifact due to known laboratory biases
Figure 1 shows that customers using performance testing methods.2 However, well documented in the literature.2
testing to select catalysts generally even the most sophisticated laboratory Albemarle has found that, despite efforts
choose high zeolite to matrix methods are not equivalent to the to reduce the high coke artifact and
(Z/M) ratio catalysts for their units, conditions in an FCC unit. regardless of the continuous efforts to
whereas customers that conduct improve testing protocols, there are still
commercial trials choose low Z/M For illustrative purposes, Figure 2 important discrepancies that can artificially
ratio catalysts.1 This is because presents a general comparison of affect the outcome of the selection
the catalyst with the optimum the coke selectivity deltas observed process. This is critical because commercial
performance in a commercial between two catalysts with differing FCC unit performance is the definitive
FCC unit is often not necessarily technologies. The first bar in the top benchmark for measuring the success of a
the catalyst that shows the best panel represents the contributions of catalyst, not laboratory results.
performance in the laboratory. deactivation plus testing protocols
toward the total coke selectivity delta Consequently, Albemarle has spent
observed in the laboratory. The large considerable time and effort in applying

100
Proportion of catalyst type selected by

90 High Z/M COKE SELECTIVITY DELTA BETWEEN TWO CATALYSTS (WT%)


80 Low Z/M
each type of customer (%)

70 Contribution to coke delta from legacy Contribution to coke delta from legacy
deactivation protocol testing protocol
60
50 Legacy
40 Large coke delta measured in the lab, grossly overpredicts FCC unit coke delta testing
protocols
30
20
10 FCC coke delta Large gap between lab and commercial reality “testing artifact”
0
Testing Non-testing
Contribution Contribution
from advanced from advanced
deactivation protocol testing protocol
Figure 1: Opposing catalyst choices are seen
in residue applications for refiners that test Advanced
and those that do not test. Smaller coke in the lab but still larger than in testing
the FCC unit protocols

FCC unit
coke delta Smaller gap, but still
relevant

Figure 2: Coke selectivity deltas observed in the laboratory compared with those in the FCC unit.

10 ALBEMARLE CATALYST COURIER ISSUE 84


ALBEMARLE HAS DEVELOPED AND OFFERS
TWO COKE CORRECTION MODELS TO ADJUST
LABORATORY DATA TO REFLECT A CATALYST’S
PERFORMANCE IN AN FCC UNIT BETTER.

the available commercial data to From a reaction mechanism point of Two models
developing mathematical methods to view, it is important to remember there In light of the above, Albemarle
close the gap between laboratory testing are five contributors to the amount of has developed and offers two
and reality. coke an FCC catalyst produces: coke correction models to adjust
a) catalytic coke: a by-product of laboratory data to reflect a catalyst’s
The underlying concept catalytic cracking series reactions performance in an FCC unit better. It
Looking at 19 commercial side-by- b) non-distillable coke resulting from is well established that metal effects
side comparisons has shown that incomplete feed vaporization on laboratory-deactivated catalysts
a) there is no difference in regenerator c) contaminant (or metals) coke exaggerate both the hydrogen and
temperature between low and high catalyzed by metals deposited on the the coke yield compared with those
Z/M ratio catalysts on average, i.e., catalyst observed in an FCC unit, so the Metals
there is no difference on average in d) feed (or Conradson carbon) coke, Coke Correction Model adjusts the
coke selectivity when comparing them which is typically higher for resid laboratory coke using a stoichiometric
at similar activities; and b) it follows feedstocks relationship between coke and hydrogen
that catalysts based on low Z/M e) strippable coke, which has been yields. This model is very effective in
ratio technology, such as Albemarle’s found to be higher for catalysts with accounting for metals-driven coke yield
UPGRADER™, AFX™, ACTION® and mass transfer limitations (i.e. low differences between catalysts in the
AMBER™ families, would not result accessibility). laboratory and catalysts in the FCC unit.
in excessive increases in delta coke
or regenerator temperatures, thus The catalytic and metal coke The second method is a Lumped Coke
contradicting what is typically found contributions are catalytically driven, Correction Model that accounts for all
during laboratory testing.3 In short, whereas the non-distillable and the five contributions to coke make. The
the coke selectivity difference between Conradson carbon contributions are, to concept behind this correction model
catalysts is exaggerated in testing and differing extents, the result of thermal is for a refiner to develop a correction
the evidence clearly demonstrates the coking or high-molecular-weight factor between laboratory coke and FCC
need to develop and apply a coke yield material adsorbed on the catalyst unit coke. To do this, a refiner needs to
correction to laboratory data. because of incomplete evaporation. conduct commercial trials with different
The last one, strippable coke, is the catalyst technologies, i.e., a low versus
result of incomplete stripping and is a high Z/M ratio catalyst, in the
not due to chemical reactions. >>>
ALBEMARLE CATALYST COURIER ISSUE 84 11
TECHNICAL FOCUS

>>>
FCC unit. If a refiner does not have such This article, to be continued in future
References
data, Albemarle offers a robust estimate Catalyst Courier issues, describes the 1
Pouwels, C. and Bruno, K.: “Deciding on the
of this correction factor based on 19 need for and concepts behind coke best FCC catalyst: The sense and nonsense of
FCC unit side-by-side comparisons.2 correction methods. Future articles selecting the best FCC catalyst by laboratory
will elucidate these methods and testing. Part 1: Introduction and case study,”
models in more detail and provide Catalyst Courier (2013) 81, 18–19
It is important to mention that some 2
Pouwels, C. and Bruno, K.: “Better catalyst
refiners have already begun correcting suggestions for developing correction evaluation strategies for maximizing FCCU
their laboratory data to reflect FCC unit factors with application examples. margins,” paper AM-13-05 presented at
performance better. A few have taken Albemarle’s goal is to develop and Annual Meeting of the AFPM in San Antonio,
the first step and have corrected for offer coke correction models that are Texas, USA (March 17–19, 2013)
commercially validated, scientifically
3
Pouwels, C. and Bruno, K.: “Deciding on the
metals coke using laboratory hydrogen
best FCC catalyst: The sense and nonsense of
yields in a manner similar to that in sound, simple and unbiased in that selecting the best FCC catalyst by laboratory
Albemarle’s Metals Coke Correction they can be applied to any FCC testing. Part 2: Commercial cases refuting
Model. Others have taken a more catalyst manufacturing technology the laboratory coke penalty for low Z/M ratio
holistic approach similar to that in the and to any dataset, regardless of the catalysts,” Catalyst Courier (2013/14) 82, 8–9
Lumped Coke Correction Model and deactivation or testing protocol used.
have made a total coke (not just metals
coke) adjustment based on differences
in coke make between the laboratory
and their FCC units. FOR MORE INFORMATION, CONTACT:
Raul Arriaga
Email: raul.arriaga@albemarle.com
Ken Bruno
Email: ken.bruno@albemarle.com

12 ALBEMARLE CATALYST COURIER ISSUE 84


TECHNICAL FOCUS

MAKE THE BEST DECISIONS ABOUT CATALYST TESTING


Where to spend FCC research and development resources for better catalyst selection

Catalyst Courier1, 2, 3 has reported When equilibrium catalysts (E-cat) of b) excessive dehydrogenation activity of
that refiners selecting their catalysts both were tested in a circulating pilot metals, which in combination with a)
through laboratory testing (testing plant, a coke penalty was seen. When multiplies the effect
refiners) predominantly use high tested in a bench-scale ACE unit, this c) improper laboratory conditions for
zeolite to matrix (Z/M) ratio coke penalty was even larger. This simulating realistic morphology
catalysts, unlike refiners that do illustrates that the test introduces a changes such as accessibility decline.
not test and have optimized their coke artifact the magnitude of which
FCC operations with moderate or is determined by the type of testing Several elements also contribute to the
low Z/M ratio catalysts. These days, apparatus and the protocol used. coke artifact in testing. The following
Albemarle sees several “testing differences between a real FCC unit
refiners” taking a careful approach Both catalysts were tested in a pilot and laboratory testing are important:
in back-to-back trials on low(er) plant (PP) after laboratory deactivation a) Too long a contact time causes extra
Z/M ratio catalysts and successfully by cyclic propene steaming (CPS) catalytic and metals coke.
increasing their cracking margins. and observed a substantial increase b) If stripping times are too long, the
in the coke penalty for the low Z/M differences in soft coke cannot be
Why is there a difference and how can ratio catalyst compared with the determined.
testing refiners that rely on laboratory E-cats (Figure 1). This shows that the c) An unrealistically low hydrocarbon
results make the best decisions on the deactivation also introduces a coke pressure means that the chemical
catalysts to use and not be limited to artifact. In addition, a comparison reactions, for instance, hydrogen
high Z/M ratio catalysts? This article was made by testing the laboratory- transfer, are not properly simulated.
explains several of the shortcomings of deactivated catalysts in a bench-scale
laboratory testing and how these can ACE unit. The difference in coke yield Deactivation issues
be overcome. between both catalysts increased Laboratory deactivation of FCC
further, which illustrates how the coke catalysts typically tries to meet E-cat
Laboratory testing has been shown penalties of deactivation and testing properties such as surface area, zeolite
to lead to unrealistic coke artifacts for methods are cumulative. unit cell size and catalyst activity, and,
low Z/M ratio catalysts.3 In addition, in the case of resid applications, nickel
the slurry benefit in the FCC unit is Contributions to the coke artifact and vanadium levels. The average
typically substantially larger than is Although both deactivation and age of deactivated catalyst particles is
seen in laboratory tests. This leads to testing contribute to the coke artifact, several months, but research centers
smaller economical margins for low Z/M several factors influence the difference generally squeeze deactivation into
ratio catalysts. Most deactivation and between E-cat and laboratory two days or less. Consequently, they
testing protocols amplify the sensitive deactivation, including increase the deactivation temperature
coke signals and overshadow any slurry a) insufficient hydrothermal and the steam to speed up deactivation
reduction, and refiners often evaluate deactivation of the matrix and meet the target properties. Thus,
their test results on a constant coke
yield basis, which worsens the picture. 2.0 >>>
Coke (low Z/M)/coke (high Z/M)

1.8
The coke artifact 1.6
3 unit + deactivation effect

The coke artifact is due to insufficient


1.4
simulation in the deactivation 1 unit effect 2 deactivation effect Figure 1:
procedure and the testing step. 1.2 Contribution
of type of
One refiner compared a high with 1.0 deactivation
a low Z/M ratio catalyst and the and type of
0.8
coke selectivity of both catalysts, test to the
represented by the horizontal line in 0.6 coke artifact.
E-cat E-cat E-cat CPS E-cat CPS
Figure 1, was the same in the FCC unit. PP bench PP PP PP bench

ALBEMARLE CATALYST COURIER ISSUE 84 13


TECHNICAL FOCUS

>>>
very severe deactivation takes place Accessibility Next steps
and the catalyst deactivates faster Although most laboratories focus on Knowing these shortcomings
compared with reality (Table 1). mimicking surface area and activity, makes it possible to develop better
they rarely take into account the deactivation and testing units and
This generally leads to an imbalance physical degradation of catalyst particle protocols. However, in Albemarle’s
in deactivation between zeolite and morphology. This process, during which experience, this is time-consuming
matrix. Indeed, the deactivation the particles get denser over time, is and unlikely to solve all the problems.
rate of zeolite is higher than that of complex and slow and the catalyst The issues described are some of the
alumina matrices (Figure 2). However, often loses its accessibility (expressed more important ones, but not all of
typical “quick” laboratory deactivation by the Albemarle Accessibility Index, them. Moreover, the ideal laboratory
methods with high temperatures and AAI), particularly when resid is being deactivation protocol would take
short times do not facilitate matching processed. As the AAI is a crucial considerable time to match a real
the E-cat’s zeolite and matrix activity. catalyst parameter, poor simulation E-cat, and if an E-cat can be perfectly
will lead to incorrect test results. The mimicked, the test unit and protocols
Comparing E-cats with laboratory- difference between good catalysts would need modification.
deactivated catalysts shows that the (high AAI) and mediocre catalysts (low
zeolite is relatively over-deactivated AAI) is thus neglected. With decades of experience and
in the laboratory and that the matrix
knowledge of FCC units and laboratory
is relatively too active. Table 2 shows Figure 4 shows that E-cat generally has testing, Albemarle believes that no
that although the matrix surface area a lower AAI than the fresh catalyst. single deactivation method and test
is equal, the zeolite surface area from However, for the most common unit could achieve identical coke and
the laboratory is too low, which is also laboratory deactivation methods, the slurry yields to those in an FCC unit.
reflected in the unit cell size. If quicker AAI may go up or remain relatively It is, however, important to develop
deactivation is applied, the zeolite high. This is valid for steaming and knowledge and experience to relate
surface area can be matched but then cyclic deactivation, and for CPS. Only test results to commercial performance
the matrix surface area in the laboratory- when dedicated and time-consuming using a translation or correction
deactivated catalyst is too high. methods are applied under more method. Albemarle recommends
realistic deactivation conditions, can “testing refiners” should expend effort
To get a good match in zeolite and
the AAI decline be simulated. One in developing such relationships and
matrix deactivation, there needs to be
Albemarle method, CD ALFA,4 includes methods. Albemarle is happy to help
a way to change the relative rates of
metals such as iron and calcium, but and can offer its models as a first step.
deactivation for zeolite and matrix, i.e.,
it is time-consuming and seldom For more information see “Improving
a method whereby the deactivation of
embraced by research centers. FCC catalyst selection by adjusting
matrix speeds up to a rate equal to that
laboratory data,” page 10.
of the zeolite or vice versa.

A generic tool laboratories use is the


LABORATORY FCC UNIT
deactivation temperature. Generally,
laboratories increase the severity by DEACTIVATED CATALYST’S AGE 5 h to 2 d 2–12 months
increasing the temperature rather than TEMPERATURE, °C 788+ 680–740
lowering it. As illustrated in Figure 3,
STEAM, % 50–100 5–10
an increase in temperature from 788
to 815°C enhances zeolite deactivation PRESSURE, BARG Ambient 1.5–3
but has little effect on matrix
deactivation. The imbalance between Table 1: The main differences in process conditions between the laboratory and the FCC unit.
zeolite and matrix deactivation is
thus increased. In conclusion, the
temperature should be lower, but E-CAT DEACTIVATED CATALYST
longer deactivation will be required MATRIX SURFACE AREA, M /G 2
74 74
to match the E-cat. Most laboratories
ZEOLITE SURFACE AREA, M /G2
38 31
do not want to take more time to
deactivate the catalyst. UNIT CELL SIZE, Å 24.38 24.35

Table 2: Imbalance in zeolite and matrix deactivation.

14 ALBEMARLE CATALYST COURIER ISSUE 82


References
1
Pouwels, C. and Bruno, K.: “Deciding on
the best FCC catalyst. Part 1: Introduction
and case study,” Catalyst Courier (2013) 81,
17–19
2
Pouwels, C. and Bruno, K.: “Deciding on the
best FCC catalyst. Part 2: Commercial cases
refuting the laboratory penalty for low Z/M
ratio catalysts,” Catalyst Courier (2013/14)
82, 8–9
3
Pouwels, C. and Bruno, K.: “Deciding on the
best FCC catalyst. Part 3: The implications of
using test data,” Catalyst Courier 83, 19–21
4
Rainer, D. R., Rautiainen, E. and Imhof, P.:
“Novel lab-scale deactivation method for
FCC catalyst: Inducing realistic accessibility
responses to iron poisoning,” Applied Catalysis
A: General (2003) 249 (1), 69–80

FOR MORE INFORMATION, CONTACT:


Carel Pouwels
WITH DECADES OF EXPERIENCE AND
Email: carel.pouwels@albemarle.com
Ken Bruno KNOWLEDGE OF FCC UNITS AND
Email: ken.bruno@albemarle.com
LABORATORY TESTING, ALBEMARLE
BELIEVES THAT NO SINGLE DEACTIVATION
METHOD AND TEST UNIT COULD
ACHIEVE IDENTICAL COKE AND SLURRY
YIELDS TO THOSE IN AN FCC UNIT.

High-accessibility catalyst
100 100 20
Matrix Matrix
Surface area retention %

Surface area retention %

80 Zeolite 80 Zeolite 16 Fresh

60 60 12
AAI

Low-accessibility catalyst
40 40 8

4 Fresh
20 20

0 0 4
0 1 2 3 4 5 6 785 790 795 800 805 810 815 820
t
ing

CD

ea

ing

CD

fa
ca

ca

Al
Al

Relative age of fraction, E-cat


E-

E-
m

am

CD

Deactivation temperature, °C
ea

CD

< Fresh young Old >


St

St

Figure 2: Deactivation rates for zeolite and Figure 3: The effect of temperature on the Figure 4: The common laboratory deactivation
matrix over time. deactivation rates of zeolite and matrix. methods cannot simulate catalyst accessibility
properly.

ALBEMARLE CATALYST COURIER ISSUE 84 15


TECHNICAL FOCUS

DEVISING THE BEST FCC SOLUTIONS


Albemarle opts for a new FCC process simulator

Albemarle relies on FCC process Real-world comparison The benefits


simulations to help it provide the The decision to adopt a new modeling Besides improving predictive capabilities,
best possible solutions for customers. platform came after a year of intensive sharing the same modeling platform
They are used when monitoring the side-by-side technical evaluations of both as our customers provides other
performance of customers’ FCC units simulators using real-world datasets. advantages. First, we both start with
to help in normalizing refinery data Each model was set up with data taken exactly the same dataset, which is
and projecting them to a constant before an operational change and then already in the proper format for use by
basis; for comparing catalyst the predictions of the perturbations the model. Any necessary assumptions
changes; when suggesting the best were compared. Both models gave or corrections to the data are applied
operational set points to maximize good predictions of situations where by both of us. Sharing the model
profitability with Albemarle catalysts; independent process variables, such as enables us to begin our technical
and when selecting the optimal flow rates, pressures and temperature, communications at a deeper level; we no
catalyst formulation for a particular were changed. FCC-SIM, however, longer need to discuss whether or not
refiner’s needs. demonstrated a clear advantage when it differences in model results are due to
came to predicting operational changes different models being used to analyze
In October 2014, Albemarle updated pertaining to the regenerator and the dataset. Furthermore, we use the
its FCC process simulator to FCC-SIM, the predictions of feed compositional same terminology when discussing
which was developed by KBC Advanced changes. This was because the FCC- the modeling process and the model
Technologies and is widely used by refiners SIM model was more sophisticated in results. We can also collaborate with our
to simulate FCC units. This replaces the terms of stream synthesis, hardware customers in sharing knowledge and
CatOp FCC simulator also from KBC. configurations and coke burning kinetics. developing and refining best practices.

An example of an FCC-SIM flow sheet.

N2 inerts Sour water


Inerts mixer
88.8 Flue gas I

CO2 inerts Wet


FCC meter gas

88.8
FCC
CO inerts Reactor Wet gas
inerts
Regenerator steam compressor
steam
Combined
feed Overhead
Effluent liquid
Regenerator
air I HCN
VGO feed
FCC LCO
coke
Resid feed ICO
Main
fractionator
FCC
Extra feed HCO

Total CLO
feed
Feed Riser
mixer injection
steam
16 ALBEMARLE CATALYST COURIER ISSUE 84
The common modeling platform enhances
Albemarle’s ability to bring an external
perspective to day-to-day operations in a
refinery. Our 30 technical specialists located
worldwide bring with them a vast breadth of
experience and, combined with the FCC-SIM
modeling tool, provide refiners with quantified
actionable advice pertaining to catalyst
strategy, troubleshooting and optimization.

We encourage all refiners who license


FCC-SIM from KBC to begin sharing with
us their data in the FCC-SIM format and for
users of version 4 and above to exchange
process flow sheets. The synergistic benefit
of utilizing the same modeling platform
provides greater efficiency in exchanging
data and information; a more transparent
modeling experience for both unit monitoring
and catalyst predictions; and; ultimately;
an unprecedented potential for detailed
technical collaboration to yielding the best
possible profitability for our customers.

Dry
OUR 30 TECHNICAL SPECIALISTS
gas LOCATED ACROSS THE GLOBE
High-pressure
wet gas BRING WITH THEM A VAST
Sour
water BREADTH OF EXPERIENCE AND,
Mixed
II
COMBINED WITH THE FCC-SIM
overhead
Alky MODELING TOOL, PROVIDE REFINERS
feed
WITH QUANTIFIED ACTIONABLE
Overhead
mixer 88.8 ADVICE PERTAINING TO CATALYST
LCN STRATEGY, TROUBLESHOOTING AND
OPTIMIZATION.

FOR MORE INFORMATION, CONTACT:


Alan Kramer
Email: alan.kramer@albemarle.com

ALBEMARLE CATALYST COURIER ISSUE 84 17


TECHNICAL FOCUS

COMBUSTION PROMOTERS ON CALL


Albemarle’s combustion promoters can resolve operational and environmental issues in FCC units.

A well-tuned FCC unit will exhibit Operation is possible with some level of pressure drop across this valve may
exceptional selectivity towards the afterburn; however, high temperatures make circulation irregular. Combustion
desired products and will run against and thermal cycling lead to a decreased promoters solve these issues by pushing
multiple operating limits dictated lifetime for the metallurgy in the the coke burn into the dense phase
by both equipment and regulatory plenum and cyclones. These same where the energy is substantially
law. As a unit ages and refiners effects accelerate deactivation of all absorbed by the recirculating catalyst.
push design limits, acute and chronic catalysts and result in higher fresh
issues can occur. For afterburn, catalyst consumption. Minor afterburn Matching “medicine” to
the prognosis is bright with may be controllable with additional air, “malady”
proper application of Albemarle’s but the blower capacity or the available Different solutions work for different
combustion promoters. contact time in the dense phase can situations, and Albemarle offers a full
limit success. portfolio of solutions (Table 1). KOC‑15™
The afterburn issue is a platinum-based product with a
FCC issues can be generally classified Afterburn can negatively affect catalyst demonstrated history of high efficacy. The
as operational or environmental. circulation and coke make. Energy is key ingredient is delivered on a special
One common operational problem is wasted by heating the regenerator’s support that provides high average bulk
afterburn, which plagues some units metal and is unavailable for cracking density and excellent particle integrity.
chronically and others unexpectedly. oil in the riser. As a result, the FCC unit This same support widely disperses
Afterburn is a term describing makes more coke and less valuable the platinum and minimizes sintering
significant combustion from carbon products by weight balance, but has a under FCC conditions. KOC-15 has
monoxide to carbon dioxide in the lower dense bed temperature and higher demonstrated more active sites and
dilute rather than the dense regenerator catalyst circulation. The regenerator reduced afterburn compared with
phase. The dilute phase becomes too slide valve provides this circulation competitors’ products during commercial
hot, as little catalyst is present to absorb by opening; however, the resultant side-by-side trials (Figure 1).
the heat of combustion. Heat spreads
throughout the cyclone and plenum
phases causing stress to the refractory
and metallic materials present.

High temperatures present in the dilute Competitor 1 Albemarle Competitor 2 Albemarle


phase may be localized because the 35
refiner has a damaged air distributor,
which leaves inadequate oxygen 30
for complete combustion in some 25
parts of the dense regenerator bed.
Afterburn, °C

20
High temperatures can also occur
throughout the entire cyclone and 15
plenum spaces. In this case, a refiner
10
needs to consider the bed level and
superficial velocity in the regenerator. 5
Operations may have shifted to create 0
inadequate residence time for oxygen
ay

ar

ay

ar

ay

ar

ay
Ju

Ju

Ju
No

No

No
Se

Ja

Se

Ja

Se

Ja
M

M
M

in the dense phase.


Figure 1: KOC-15 clearly outperforms two different competitors’ platinum-based additives. All the
promoters were added to achieve a constant platinum level of 3 ppm in the circulating inventory.

18 ALBEMARLE CATALYST COURIER ISSUE 84


A side effect of any platinum-based particle in the inventory. InsituPro is In cases calling for ELIMINOx,
promoter is increased NOx emissions, an excellent option for refiners dealing afterburn control is again rapid and,
as the oxidative power is not confined with routine afterburn and desiring as the inventory builds, the achievable
simply to carbon. For units concerned a standard treatment regimen. Dual NOx reduction compared with a
with NOx, Albemarle recommends strategies are appropriate in some platinum promoter is observable
ELIMINOx™: a non-platinum-containing circumstances. For example, a refiner within days (Figure 2).
combustion promoter. Some refiners may apply InsituPro regularly and
need to limit NOx emissions owing keep a separate stock of KOC-15 for
to agreements with the United States emergencies requiring extra promoter.
Environmental Protection Agency.
Others perhaps sell equilibrium catalyst
to refineries where the FCC unit is under
Fast-acting “medicine” FOR MORE INFORMATION, CONTACT:
Ryan Nickell
a NOx constraint. Using proprietary Whether the problem is high carbon Email: ryan.nickell@albemarle.com
monoxide emissions or high levels of
ingredients, ELIMINOx provides effective
afterburn, unhealthy operations can be
afterburn control with 40–70% lower
quickly remedied. Once a combustion
NOx emissions compared with a
promoter is applied, afterburn control
platinum-based promoter.
may occur within minutes. The
benefits of Albemarle’s technology
InsituPro™ technology is an exclusive compared with competitors’ products
product available only to customers are rapidly apparent. In Figure 1,
purchasing Albemarle’s FCC catalysts. afterburn controlled near 35°C with
The active ingredients are deposited competitors’ products improved to
directly onto the catalyst, so promotion below 10°C with KOC-15.
activity is present on every single

TYPICAL PRODUCT PROPERTIES


Pt promoter ELIMINOx
1200
ADDITIVE NAME KOC-15 ELIMINOx InsituPro
Base NOx
1100
Low NOx
Combustion Combustion
1000 APPLICATION combustion
promotion promotion promotion
900
NOx, ppm

ATTRITION INDEX, WT% 1.5 2.7


800
AVERAGE BULK
700 0.85 0.88
DENSITY, G/ML
Reduced NOx
Same
600 SURFACE AREA, M2/G 105 110
as base
500 PARTICLE SIZE catalyst
7 10
DISTRIBUTION (0–40), %
400
-7 0 7 14
Days PARTICLE SIZE
2 1
DISTRIBUTION (0–20), %

Figure 2: The reduction in NOx emissions by using ELIMINOx can be up to Table 1: Albemarle’s combustion promoters.
70%. The 40% NOx reduction shown is typical.

ALBEMARLE CATALYST COURIER ISSUE 84 19


TECHNICAL FOCUS

REACHING FOR THE STARS


REACT™ technology to achieve a major milestone this year.

Since its introduction in 2003, Today’s challenging market conditions hydroprocessing catalysts. This greatly
REACT technology has become for the refining industry ask for enhances the value and flexibility of
a very successful and proven creativity, flexibility and efficiency: these catalysts for refiners. Depending
method for optimizing the use of creativity in the sense of collaborating on actual metal values, cost savings up
all STARS® catalysts. Albemarle and with partners to optimize products to 60% are achievable. If necessary, a
Nippon Ketjen developed REACT and minimize waste streams; flexibility performance guarantee for combined
technology to help maximize to address rapidly changing market REACT–fresh hydrotreater loadings can
catalyst value. The performance of conditions; and efficiency in working be discussed and granted.
used STARS catalysts is restored so that no valuable streams, products
by a special regeneration process and capital are lost. Annually, about 40,000 t of valuable
followed by redispersion of the spent hydroprocessing catalyst is
active metals. Type II active sites Enhancing value and flexibility disposed of after just one cycle. A
are recreated and protected by an Albemarle, with its partners Eurecat good part of this catalyst could be
organic coating, just as with fresh and Porocel have a long history of reused by applying regeneration and
STARS catalysts. optimizing the use of hydroprocessing REACT technology. In addition to the
catalyst and REACT-ivating Albemarle’s obvious economic benefits, reducing
In 2015, Albemarle is expecting to reach STARS catalysts close to fresh this waste by introducing a virtuous
a significant milestone: REACT-ivating activity levels. Proper planning with catalyst recycle loop would also help
50,000 t of spent STARS catalysts. good understanding of multi-cycle to minimize the environmental impact
economics can extend the lifetimes of of the industry.

Eurecat SAS – France Porocel – Luxembourg Figure 1: Global licensed locations for
REACT technology.
Ecorigen – Italy
Tricat – Germany

Tricat – USA
Eurecat – USA

Porocel – USA

Eurecat –
India

Al Bilad Catalyst – Porocel CRS – Nippon Ketjen –


Saudi Arabia Singapore Eurecat plant Japan

20 ALBEMARLE CATALYST COURIER ISSUE 84


By the end of 2014, more than Recently, Albemarle has become
150 refiners had regularly used REACT aware of alternate rejuvenation
technology in 750 hydrotreaters. technologies for a variety of
hydroprocessing catalysts. The
Multiple Eurecat and Porocel plants
company would like to point out
across the globe are capable of
that it does not endorse these
applying REACT technology to alternative rejuvenation technologies
spent STARS catalysts (Figure 1). or recommend or endorse their use
Some catalyst batches have been with STARS catalysts. Albemarle only
REACT‑ivated three or four times recommends and endorses the use of
(Figure 2). REACT technology for rejuvenation
of STARS catalysts. Using the
All REACT-ivated catalysts are tested for proven REACT technology offered
their chemical and physical properties by Albemarle and Nippon Ketjen
and, on request, for activity and certified licensees around the world,
means refiners can expect maximum
pressure drop. Refiners can discuss the
activity recovery during multiple
options for spent catalyst management
cycles of use of STARS catalysts.
with Albemarle. The emphasis will
lie on the value of collaborating with
Albemarle and its partners in terms of
catalyst pool management and optimal
reactor loading design. The use of
REACT-ivated catalysts in tailored, smart
reactor loading concepts can provide
the flexibility demanded in today’s 400
Weighted average bed temperature, °C

dynamic marketplace. 390


380
With the help of its wealth of 370
experience and specified reference 360
cases, Albemarle can demonstrate 350
how it is possible to reduce catalyst 340 100% fresh
costs efficiently over multiple cycles 330 30% REACT + 70% fresh
for hydrotreating operations without 50% REACT + 50% fresh
320
compromising performance and thus
310
further improve the sustainability of
300
the refining industry. 0 5 10 15 20 25
Time onstream, months
FOR MORE INFORMATION, CONTACT:
Figure 2: Unit performance over three cycles with KF 848.
Peter-Paul Langerak
Email: peter-paul.langerak@albemarle.com

ALBEMARLE CATALYST COURIER ISSUE 84 21


TECHNICAL FOCUS

FLEXIBILITY FOR FCC PRETREATMENT


Meeting the challenges of clean fuel hydrotreating needs

Refiners increasingly need to How FCC-PT can help customers diesel product. North American units
produce ultra-low-sulfur gasoline FCC-PT is an increasingly important tend to fall primarily in the moderate-to-
and to increase diesel fuel output, refinery process. Unlike processes that high pressure range. More than 50% of
which can be challenging. FCC produce clean fuel products directly, the world’s moderate pressure FCC-PT
pretreatment (FCC‑PT) units are, its economic value largely derives from units and more than 75% of the high-
therefore, more important than ever how well it improves FCC unit product pressure units are in North America.
and they require robust and reliable yields, product qualities and operations. Although many of these units focus on
catalyst systems to give them high Depending on the refinery, the key HDS, some focus on maximizing HDN/
activity and good stability. objectives for FCC-PT operations may HDA. However, there are relatively fewer
be to units in the Americas that strive to
However, no single FCC-PT unit caters a) maintain a low product sulfur level increase diesel yield compared with the
equally for all clean fuel hydrotreating with high hydrodesulphurization (HDS) rest of the world.
needs. The oil feedstocks come from to meet environmental regulations on
many different regions of the world gasoline sulfur content and FCC unit Albemarle’s viewpoint
and have differing compositions and SOx emissions Albemarle has traditionally had most
contaminants. FCC-PT units also b) reduce nitrogen and aromatics levels success in the FCC-PT segment in
process many types of heavy, dirty oil by maximizing HDN and HDA for supplying CoMo and NiCoMo catalysts
across a very wide range of operating improving FCC unit product yields, to low-to-moderate pressure FCC‑PT
conditions. Individual refiners’ primary selectivities and operations units where the primary objective
operating objectives can also vary from c) increase the conversion of VGO to was to achieve a low product sulfur
targeting constant product sulfur to diesel-range products. target. In recent years, product sulfur
maximizing hydrodenitrogenation (HDN) targets have become even lower and
and hydrodearomatization (HDA), and/ In addition, controlling FCC-PT catalyst the need for more active and stable
or increasing conversion to produce fill costs and achieving target cycle catalysts has increased. In addition, for
more diesel. lengths are generally high priorities for moderate-to-high-pressure catalytic feed
most refiners.
Albemarle has determined that
VGO STAX® –FCC-PT is a preferred No single FCC-PT unit is characteristic 60
technology solution to enable of this process application as a whole.
customers to meet the FCC-PT The existing units are designed and 50
challenges in their refineries. It has operated to fit specific refinery operating
wide-ranging global refinery operating strategies and objectives. As a result,
insights that help it to accommodate 40
FCC-PT units cover a broad range of feed
customers’ needs, constraints and properties and operating variables. These
opportunities. Strong process and units can be characterized by operating 30
technology application expertise objectives and hydrogen partial pressure
also enables Albemarle to advise (ppH2) (Figure 1). “Low” means inlet 20
customers on the preferred catalyst ppH2 <55 bar; “moderate” implies an
systems and operating tactics that inlet ppH2 between 55 and 100 bar; and
will help them to meet their operating 10
“high” means a ppH2 >100 bar.
objectives. To bolster this technical
expertise, Albemarle has a proprietary Figure 1 shows that units in Europe, 0
computer process modeling capability China Asia Europe Middle North Latin
the Middle East and India are mostly in Pacific East & America America
that gives highly reliable performance the low-to-moderate pressure range. India
estimates and is used to generate These units are typically operated to High P Mod P Low P
and assess catalyst loading design achieve deep HDS and, in some cases,
recommendations for customer units. Figure 1: Global segmentation of FCC-PT units by
to increase conversion of VGO feed to geographic region and operating pressure.

22 ALBEMARLE CATALYST COURIER ISSUE 84


hydrotreatment (CFHT) units, the need for three reaction zones for more than still relatively slow. Thus, NiCoMo
deeper HDN and greater HDA to improve 10 years. VGO STAX–FCC-PT technology, catalysts with their balance of HDS and
FCC yields and selectivities has increased. however, currently covers only two HDN reactions can be very beneficial
reaction zones, as FCC-PT operations in this part of the reactor, especially at
To meet these market needs, Albemarle do not go deep enough in HDS/HDN moderate ppH2. The conversion of VGO
has conducted research across a broad to achieve the reaction conditions feed to lighter products in these units
spectrum of customer operations on how experienced in Zone 3. Figure 2 illustrates is essentially due to thermal conversion
best to help customers meet their needs. the basic concepts of VGO STAX–FCC‑PT caused by increased temperature.
During this research, it became clear that technology by showing the types of
variations in FCC-PT operating conditions reactions occurring in each zone and the Units in the moderate-to-high pressure-
and unit objectives and constraints inhibitors slowing these reactions. operating regime may have any of the
make it practically impossible for a single three operating objectives. As ppH2
catalyst to fulfill all a refiner’s needs Most low-to-moderate pressure units increases, achieving increased HDN/HDA
and wants. Consequently, Albemarle have constant HDS as their primary tends to become increasingly important.
concluded that STAX systems for FCC-PT objective. In Zone 1, the top portion of For applications where overall catalyst
are preferable for almost all applications. the reactor where direct desulfurization system HDS activity is the primary
(DDS) is the predominant reaction, objective, using CoMo and/or NiCoMo
STAX technology overview CoMo and NiCoMo catalysts are ideal catalysts in both zones 1 and 2 can still be
STAX is Albemarle’s proprietary for boosting HDS reaction rates. HDN effective for meeting unit objectives. To
process technology for designing a reaction rates tend to be limited by achieve moderate levels of HDN and HDA,
catalyst system to meet unit objectives low pressure, and nitrogen inhibition using NiCoMo catalyst in Zone 2 with
within given operating conditions and further slows HDN and HDA rates in CoMo or NiCoMo catalyst in Zone 1 may
constraints. This technology accounts Zone 1. When intermediate product be sufficient to meet the goals. Achieving
for the chemical reactions and reaction sulfur and nitrogen fall to certain levels, deep levels of HDN/HDA will generally
environments encountered in the Zone 2 is achieved. HDS reactions can require NiMo catalyst in Zone 2. However,
different zones of the reactor and occur via a combination of DDS and for units that are HDS-activity-limited in
matches the deployment of catalyst hydrogenation reactions at an overall any way, CoMo and/or NiCoMo catalysts
benefits with each zone to optimize the slower rate than in Zone 1. Owing to are beneficial in Zone 1 and, in some
overall catalyst system’s performance. the lower concentration of nitrogen, cases, the upper portion of Zone 2 as well.
Ultra-low-sulfur diesel STAX technology HDN and HDA reactions will be faster
has been successful in applications with compared with those in Zone 1, though

ZONE 1 (30–60 VOL%) ZONE 2 (40–70 VOL%) Reaction zones vary in length and
H2 partial pressure Higher Lower
position during cycle

Main HDS reaction Direct + hydrogen Catalyst application strategy


ZONE 1 Direct HDS
Main HDS inhibitor Organic nitrogen must account for Zone 1 growth
Main HDN/HDA reaction Hydrogenation Hydrogenation and Zone 2 shrinkage throughout
Main HDN/HDA inhibitor organic nitrogen, aromatics Organic nitrogen, aromatics the cycle, and operating
HDS reaction rate Fast Slow
conditions and constraints and
HDN/HDA reaction rate Very slow Slow product targets
ZONE 2
CoMo (low to medium P) CoMo (<55 bar ppH2)
Preferred catalyst types (general (Ni)CoMo (medium P) (Ni)CoMo (medium ppH2)
guidance; may vary for specific cases) NiMo (high P) NiMo (>90 bar ppH2)

Figure 2: The VGO STAX-FCC-PT reaction zone concept.

ALBEMARLE CATALYST COURIER ISSUE 84 23


TECHNICAL FOCUS

>>>
VGO STAX–FCC-PT commercial and 2-ppmw nickel plus vanadium. at which the feed must be introduced
examples Its inlet ppH2 is about 100 bar and its and/or require gas-phase sulfiding of
objectives are to produce FCC feed with the catalyst. Both these limitations
This STAX technology solution has
1500-ppmw sulfur and <600-ppmw can cause the organic additive used
had numerous successful applications
nitrogen, and to achieve a four-year to protect and maintain the Type II
in FCC‑PT units around the world.
cycle length. Based on its process model active metal configuration to degrade
A couple of different commercial
projections, Albemarle designed a on STARS catalysts. Using PROTECT®
application examples will help to
guard catalyst system to remove nickel, treatment enables STARS catalysts to be
illustrate the principle and the results.
vanadium and silicon, and to protect fully activated under these constraints,
The first example is a low-pressure
against polymerization causing pressure but it adds to the overall catalyst fill
CFHT unit with an inlet ppH2 of 53 bar
drop build-up, and applied a VGO STAX cost. Conventional Type I catalysts are
(770 psi) that processes a straight-
NiCoMo/NiMo STARS catalyst system in unaffected by these unit constraints
run VGO feed with 2-wt% sulfur and
the main reactor. As shown in Figure 4, and Albemarle has both NiCoMo and
1600-ppmw nitrogen. This unit runs in
this STAX catalyst system is approaching NiMo Type I catalysts in its FCC-PT
constant product sulfur mode targeting
three years on oil and its actual catalyst portfolio to overcome these unit
200-ppmw FCC feed sulfur to produce
performance corresponds very well with limitations, see page 26.
FCC gasoline with 10-ppmw sulfur. Its
the process model projections.
STAX catalyst system is designed with
CoMo and NiCoMo STARS® catalysts
and achieves nearly a six-year cycle Commercial FCC-PT unit
length (Figure 3). start-up constraints
STARS catalysts have a long history
The second example is a high-pressure (15 years) of successful FCC-PT
CFHT unit that processes a feed blend applications worldwide. Despite their FOR MORE INFORMATION, CONTACT:
containing HVGO and HCGO that has success in numerous units, some units George Anderson
Email: george.anderson@albemarle.com
3-wt% sulfur, 1500-ppmw nitrogen have limitations on the temperature

105 410

400 800
102.5
750 Actual
390 Projection
100 700
380
WABT, °C

650
WABT, °F
HDS, %

97.5
370 600 KF 905

95 550 KFR 22
360 Deactivation = 2.5°F/month
HDS
500 >40-month cycle KFR 647 KF 857
92.5 350
WABT, °C 450

90 340 400
0 500 1000 1500 2000 2500 0 200 400 600 800 1000 1200 1400

Run time, d Days on stream

Figure 3: Temperature increase rate of reaction profile and Figure 4: Commercial example 2
constant 99% HDS for commercial example 1.

24 ALBEMARLE CATALYST COURIER ISSUE 84


TECHNICAL FOCUS

ALBEMARLE’S FCC PRETREATMENT (FCC-PT)


SOLUTIONS FOR CUSTOMERS’ CHALLENGES
Portfolio revamp offers refiners wider-ranging options

Albemarle has determined that


VGO STAX®–FCC-PT is a preferred
technology solution to enable
customers to meet the FCC-PT ALBEMARLE IS CURRENTLY
challenges in their refineries. RECOMMENDING THE USE
This technology leverages the
OF KF 907 PRIMARILY IN
performance benefits of four
recently commercialized catalysts UNITS WHERE THE START-UP
that have optimized the performance CONSTRAINTS MAKE TYPE I
of customers’ units. CATALYSTS PREFERABLE.
To help meet the increasingly challenging
process objectives across the broad
spectrum of feed properties and
operating objectives encountered in
FCC-PT, Albemarle’s four latest FCC‑PT
catalysts (Table 1) provide superior
technology solutions to customers
with units spanning the full range of
FCC-PT market sub-segments. When
utilized in STAX catalyst systems, these
Ketjenfine® (KF) catalysts can help
refiners to optimize performance to
meet multiple objectives and constraints
simultaneously (Figure 1). Toward
this end, Albemarle also continuously
upgrades its proprietary computer-
based process model(s) to ensure
reliable forecasts of unit performance
with its catalysts. Based on testing
conducted by Albemarle and by
customers, these four catalysts are all in Figure 1: Albemarle’s
commercial FCC-PT units. NiMo STAX systems including KF 860 FCC‑PT catalyst portfolio.
HDN and aromatic saturation activity

For FCC-PT reaction Zone 1, where most


KF 861
of the reactions occur via hydrogenolysis,
KF 851
CoMo or NiCoMo catalysts are the
preferred STAX catalyst components STAX systems:
(Ni)CoMo coupled with NiMo
at essentially all pressure levels.
KF 780 STARS with its high relative
volume activity (RVA) for HDS and HDN
and its low loading density is ideal for
this reaction zone where it provides
(Ni)Co Mo STAX systems
10–20% higher hydrodesulfurization
(HDS) RVA than older catalysts. KF 757 KF 780 KF 905 KF 905N KF 907
KF 907 has similar high HDS and
hydrodenitrogenation (HDN) RVAs to HDS activity Type I Type II

>>>
ALBEMARLE CATALYST COURIER ISSUE 84 25
TECHNICAL FOCUS

>>>
KF 780. Because it is a Type I catalyst, STARS compared with KF 757 STARS Adding value for refiners
Albemarle is currently recommending and KF 907 compared with KF 905 As refiners face stiffer challenges in
the use of KF 907 primarily in units STARS were conducted in 2014 at low FCC-PT operations, they need to have
where the start-up constraints make and moderate pressures. These tests reliable and robust catalyst systems
Type I catalysts preferable. included several feeds and multiple available that give them high activity and
conditions to span HDS/HDN severities good stability. Albemarle’s technology
For moderate-to-high pressure ranging from low HDS/HDN conversion portfolio has been revamped with new
applications, (Ni)CoMo catalysts in to deep HDS/HDN conversion. The CoMo, NiCoMo and NiMo catalysts
Zone 1 coupled with NiMo catalysts results are shown in Figure 2, which that individually have high activity
in the bottom portion of the reactor compares RVA average values for and stability, but can give optimized
are often the preferred STAX system HDS and HDN for the four new performance in STAX catalyst systems to
components, especially if HDN and catalysts with older catalysts. However, ensure that customers achieve all their
hydrodearomatization (HDA) are key the actual performance in specific operating objectives.
objectives. KF 861 STARS is the newest applications will depend strongly on
NiMo catalyst and has the highest feed properties, operating conditions However, merely having high activity
HDN activity of any of the four FCC-PT and product property targets. catalysts available is insufficient in today’s
catalysts: generally, a 20% higher HDN
RVA than KF 851 or KF 857 STARS. It
also has relatively low loading density
and provides attractive fill costs.
PROCESS PRESSURE UNIT
KF 905N STARS catalyst is a special- CATALYST SIZES TYPE OBJECTIVE RANGE SALES
purpose trimetallic catalyst with superior
KF 780 1.3Q, 2Q CoMo STARS HDS Low to moderate 3
HDS activity coupled with high HDN
activity that meets or exceeds all the
KF 861 1.3Q, 2Q NiMo STARS HDN/HDA Moderate to high 1
NiMo catalysts except for KF 861.
Because of its high HDS and HDN
RVAs across all operating pressures, KF 905N 1.3Q, 3Q; 1.5E NiCoMo STARS HDS/HDN Low to high 11
its performance can be very good in
Zone 1 and the upper part of Zone 2. KF 907 1.3Q, 2Q; 1.5E NiCoMo Type I HDS Low to moderate 4
KF 905N has been used successfully in 11
commercial catalytic feed hydrotreatment
Table 1: New FCC-PT catalysts commercialized in 2013–2114
units and is manufactured by the Nippon
Ketjen joint venture.

Albemarle’s catalyst recommendations


to refiners for VGO STAX–FCC-PT 160
solutions are tailored to address their CONVENTIONAL STARS
140
specific needs and opportunities, so the
company recommends pilot plant tests 120
to confirm its catalyst recommendations
and performance estimates where the 100
feed and/or conditions are significantly 80
different from its previous commercial
and/or pilot plant experience. 60

40
Market trials
20
Albemarle conducted extensive
(3–5 months) market introduction tests 0
in 2013–2014 that compared KF 861 KF 851 KF 901 KF 907 KF 857 KF 861 KF 757 KF 780 KF 905 KF 905N
STARS and KF 905N STARS with KF 851
HDS RVA HDN RVA
and KF 905 STARS respectively at
moderate and high pressures. Similar
market introduction tests for KF 780 Figure 2: HDS/HDN RVAs for Albemarle FCC-PT catalysts.

26 ALBEMARLE CATALYST COURIER ISSUE 84


refining environment. Customers need ALBEMARLE’S TECHNOLOGY PORTFOLIO
those catalysts that best meet their
HAS BEEN REVAMPED WITH NEW
operating objectives and constraints.
To help with this Albemarle uses CATALYSTS THAT INDIVIDUALLY HAVE
its deep refining industry insight to HIGH ACTIVITY AND STABILITY, BUT
identify customers’ needs, constraints CAN GIVE OPTIMIZED PERFORMANCE
and opportunities, and its process
IN STAX CATALYST SYSTEMS TO ENSURE
and technology application expertise
to advise on suitable catalyst systems THAT CUSTOMERS ACHIEVE ALL THEIR
and operating tactics. Toward this end, OPERATING OBJECTIVES.
Albemarle’s proprietary computer process
model gives highly reliable performance
estimates and is used to generate
and assess catalyst loading design
recommendations for customers’ units.

Albemarle is always willing for


customers to test proposed solutions
before they are applied. The company
will conduct pilot plant tests for
individual customer units and/or
provide catalyst samples for customers
to conduct their own assessments.
Where relevant commercial experience
exists, Albemarle will share commercial
results and help prospective customers
contact existing references, if possible.
In addition, Albemarle technical
service specialists can assist customers
in preparing for unit turnarounds,
monitoring catalyst loading and unit
start-ups, monitoring unit operations
throughout the cycle and help to
troubleshoot unit problems that arise
during operations. FOR MORE INFORMATION, CONTACT:
George Anderson
Email: george.anderson@albemarle.com

PPH2 LOW MODERATE HIGH

MAIN OPERATING OBJECTIVE All NiCoMo or (Ni)CoMo/ NiMo All NiMo or (Ni)CoMo/NiMo STAX;
All (Ni)CoMo or CoMo/NiCoMo STAX;
STAX; e.g., KF 905N or KF 780/KF e.g., KF 861 or KF 905N/KF 861 or
MAXIMUM HDN/HDA e.g., KF 780 or KF 780/KF 905N
861 or KF 907/KF 851 KF 907/KF 851

All (Ni)CoMo or CoMo/NiCoMo STAX; All NiCoMo or (Ni)CoMo/NiMo STAX; All NiMo or (Ni)CoMo/NiMo STAX;
INCREASED CONVERSION
e.g., KF 780 or KF 780/KF 905N e.g., KF 905N or KF 780/KF 861 e.g., KF 861 or KF 905N/KF 861

CONSTANT (LOW) PRODUCT SULFUR; All (Ni)CoMo or (Ni)CoMo/NiMo


All (Ni)CoMo or CoMo/(Ni)CoMo All (Ni)CoMo or CoMo/NiCoMo STAX;
HIGH HDS STAX; e.g., KF 905N/KF 861 or KF
STAX; e.g., KF 780 or KF 780/KF 905N e.g., KF 780 or KF 780/KF 905N
907/KF 851

Figure 3: Preferred technology solutions for each FCC-PT operating segment.

ALBEMARLE CATALYST COURIER ISSUE 84 27


AFX
no matter the feedstock quality, from light gas oils to heavy residues, Albemarle’s AfX
catalysts provide breakthrough performance. If maximizing the propylene yield from your FCC unit is high
on your agenda, you require more than a traditional catalyst. That’s why Albemarle supplies the innovative AFX™ catalyst
technology to a majority of customers who operate to maximize propylene. Through their unique morphology with high
accessibility, highly active and selective matrices and proprietary zeolite technology, AFX catalysts deliver unsurpassed
propylene yield. Ready to raise the bar on your FCC unit’s propylene yield? it’s time to maximize your potential with AfX.

in addition to maximizing C3=, AfX also minimizes dry gas and bottoms
and delivers superior yields of transportation fuels.

For more information on Albemarle AFX catalysts or our exceptional portfolio


of products and services, call (281) 480-4747 or visit www.albemarle.com.

refininG solutions

28 ALBEMARLE CATALYST COURIER ISSUE 84

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