Professional Documents
Culture Documents
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.
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
-6 -6 0.60 0.60
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.
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
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
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.
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
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
>>>
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.
High-accessibility catalyst
100 100 20
Matrix Matrix
Surface area retention %
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
E-
m
am
CD
Deactivation temperature, °C
ea
CD
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.
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.
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.
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.
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
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.
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
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.
ZONE 1 (30–60 VOL%) ZONE 2 (40–70 VOL%) Reaction zones vary in length and
H2 partial pressure Higher Lower
position during cycle
>>>
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
Figure 3: Temperature increase rate of reaction profile and Figure 4: Commercial example 2
constant 99% HDS for commercial example 1.
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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.
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.
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
in addition to maximizing C3=, AfX also minimizes dry gas and bottoms
and delivers superior yields of transportation fuels.
refininG solutions