In this issue...

OlefinsUltra™ Sets New Standard for High Activity ZSM-5 Additive

Davison Clean Fuels Technologies-A Commercial Update
Design for Six Sigma Leads to Significant Advances in Cat Feed Hydroprocessing
The Effects of Fe Poisoning on FCC Catalysts: An Update
Davison Catalysts Presents Complete Additives Solutions
A Message from the Editor …

Since its inception, the FCC unit remains the workhorse of the modern refinery. In the sixty
years since the startup of the first commercial unit at the Standard Oil Co. of New Jersey refin-
ery in Baton Rouge, LA in 1942, more and more demands have been put on the FCC unit. The
FCC unit is no longer geared only toward maximum motor fuels production. For example, in
some regions it is now very profitable to operate the FCC unit in a mode, which, through use of
ZSM-5-based additives, generates additional volume of valuable light olefins, specifically propy-
lene and butylenes. Global demand for propylene is growing at rate significantly higher than
global GDP, and propylene production from steam crackers will not be able to keep pace. Thus,
the FCCU will be called upon to generate even more propylene for petrochemical outlets in the
near future.

Davison introduced the first ZSM-5 additive for use in the FCC unit in 1985, and has continued
to develop additives with higher activity and better physical properties, thereby allowing refiners
to push to higher and higher levels of ZSM-5 activity in the circulating catalyst inventory. In this
issue, we are pleased to introduce the latest addition to our portfolio of light olefins additive tech-
nologies, OlefinsUltra™. OlefinsUltra is the most active ZSM-5-based additive available in the
market today, and is formulated with a unique matrix system that maintains the industry-lead-
ing retention properties that have become the hallmark of this product line. In the article that
follows, the successful application of OlefinsUltra in CEPSA’s La Rabida FCC unit is described.
In this application, switching to OlefinsUltra from OlefinsMax™ (currently the most widely used
ZSM-5 additive) led to further improvement in product slate as well as a reduction in fresh cata-
lyst additions.

Planning for compliance with Tier 2 low-sulfur gasoline and ULSD regulations continues to domi-
nate the agenda for many refiners, and we at Davison and our colleagues at ART have been
working very hard to provide catalytic solutions that help reduce or eliminate the large capital
expenditures on the horizon. In this issue, we again hear from our customers as they describe
the successes of Davison’s Saturn™ catalyst for the reduction of FCC gasoline sulfur and our
RFG® catalyst family for the reduction of FCC gasoline olefins. Also included is a contribution
from ART describing the successful implementation of Six Sigma tools in new product develop-
ment, which has led to the commercialization of new state-of-the-art FCC feed hydrotreating cat-
alysts, including the APART catalyst system.

Finally, an update of our research on the effects of Fe poisoning on FCC catalysts is presented.
This remains an important issue to refiners around the world. By better understanding the
mechanisms of iron poisoning, Davison is able to provide catalysts that exhibit maximum Fe tol-
erance.

The breadth of topics in this issue shows the commitment of Davison Catalysts to the develop-
ment of new and improved products that enable refiners to more cost effectively meet the chal-
lenges ahead.

Scott K. Purnell, Ph.D., Editor

In this issue….

OlefinsUltra™ Sets New Standard for High Activity ZSM-5 Additive............page 2

By James R. D. Nee, Ph.D., Sergio Sobrinos and Fernando Sanchez, Davison
Catalysts
CEPSA’s La Rabida, Spain refinery successfully used OlefinsUltra, achieving very high
yields of propylene with substantially less additive, allowing the refiner to reduce fresh
catalyst addition rate.

Davison Catalysts Clean Fuels Technologies-A Commercial

Update.........................................................................................................................page 8
By Jeffrey W. Balko, Christopher Schult Ph.D., Silas Wong, Shahab Parva,
Richard Grove, Dave Sams, Davison Catalysts and Don Manuel, Tesoco Refining
This article presents an overview of commercial trials of RFG® catalyst at Tesoro’s Golden
Eagle refinery and Saturn™ catalyst at a mid-continent refinery.

Design for Six Sigma Leads to Significant Advances in Cat Feed

Hydroprocessing......................................................................................................page 16
By Charles W. Olsen, Ph.D., Advanced Refining Technologies
Applying Six Sigma methodology to cat feed hydroprocessing (CFH) has enabled
Advanced Refining Technologies (ART) to develop a road map for state-of-the-art CFH
catalysts and catalyst systems, such as the APART system.

The Effects of Fe Poisoning on FCC Catalysts: An Update.............................page 23

By George Yaluris, Ph.D., Davison Catalysts
This article summarizes the results of Davison’s continuous research on the effects of Fe
on FCC catalysts and the strategies refiners can follow to mitigate its contamination in
the FCCU.

Davison Catalysts Presents Complete Additives Solutions.............................page 39

By John T. Sorial, Davison Catalysts
Davison’s premier loading systems enhance the use of our value-added, premium FCC
additives.

1
 OlefinsUltraTM Sets New Standard
for High Activity ZSM-5 Additives
by
James R.D. Nee, Ph.D.,
Marketing Manager, Light Olefins Technologies
Davison Catalysts
Sergio Sobrinos, Director, Sales and Technical Service
Fernando Sanchez, Technical Sales Manager
Davison Catalysts Europe
Introduction
The demand for refinery-produced propylene is fore-
cast to increase substantially through the decade1,2
and with it, the demand for ZSM-5 additives with
even higher activity than presently available, as
operators of FCC units take advantage of economic
opportunities to maximize propylene yields for sale
to petrochemicals1,3. Although a significant amount
of steam cracker capacity is expected to come on-
stream in the next few years, much of this will utilize
ethane as the primary feedstock resulting in an over-
all decrease in the amount of propylene produced as
by-product of steam cracking4. Consequently, more
emphasis is being placed on FCC units to supply
propylene. Since demand for gasoline is forecast to
grow by only 2% compared with a 5-6% growth rate
for propylene, this difference will create economic
incentives for refiners to trade off gasoline for propy-
lene production in the FCC unit.
2
Davison Catalysts first introduced ZSM-5 based
additives in 1984 for use in FCC units where the pri-
mary role was to enhance gasoline octane. Since
then, their role has changed to that of optimizing the
yields of high value C3= and C4= olefins (while at the
same time capturing the boost in gasoline octane) at
the expense of gasoline yield. Butylene (and to a less-
er extent, propylene) is used as alkylation feedstock
to produce high octane alkylate and, since alkylate is
essentially free of sulfur and olefins, it is a key com-
ponent of the gasoline pool.
Developments by Davison Catalysts over the years
have focused on increasing the intrinsic activity of
ZSM-5 additives to enable refiners to more cost-effec-
tively maximize the yield of light olefins. The first
real breakthrough came with the introduction of
OlefinsMax®, the first such additive to contain 25%
ZSM-5 crystal, which at the time was the maximum
allowable under license. This additive rapidly estab-
 Table I
OlefinsUltra: Typical Properties
lished itself as the new benchmark for high activity
ZSM-5 additives and is still the most widely used in
the refining industry.
Recently, Davison introduced a new high perform-
ance ZSM-5 additive called OlefinsUltra™. The
intrinsic activity of this additive far exceeds even
that of OlefinsMax and it provides the highest activ-
ity per pound of any commercially proven ZSM-5
additive. Since its introduction, OlefinsUltra is being
used in six FCC units and a discussion on one of
these applications is the basis of this article.
OlefinsUltra Technology
One of the greatest challenges in the manufacture of
high activity ZSM-5 additives is the binding of the
zeolite and capturing the activity of every pound of
ZSM-5 crystal in the formulation. In OlefinsUltra, a
proprietary matrix is employed that not only pro-
duces a linear activity response with increasing
ZSM-5 crystal content but also provides excellent
attrition resistance (Table I).
The linear activity response of Davison ZSM-5 addi-
tives is well documented5-7 and as the data that fol-
lows clearly demonstrate, can be extended well
beyond that previously reported5,6.
OlefinsUltra Commercial Performance
CEPSA’s La Rabida refinery in Spain processes a
VGO feedstock in their FCC unit that contains vari-
able amounts of heavier residual hydrocarbons. The
propylene yield was typically below 10 vol% (6 wt%)
before the introduction of Davison’s OlefinsMax addi-
tive. Since this refinery has a petrochemical outlet
for propylene, economics favored further increasing
the yield of propylene from the FCC unit.
OlefinsMax, which at the time was the highest activ-
3
ity ZSM-5 additive available, was introduced in 2001
and this refiner was able to increase the yield of
propylene from the FCC unit by about 5 vol% (3
wt%).
Following its successful commercialization in the
U.S., OlefinsUltra was proposed to this refiner on the
basis that this additive would enable them to main-
tain high yields of propylene and butylenes but with
the added benefit of reduced fresh catalyst addition
rate. Since OlefinsUltra contains substantially more
ZSM-5 crystal per pound of additive, the amount of
additive required to meet their light olefins objec-
tives would be reduced, thereby alleviating dilution
of the circulating catalyst inventory. Long term,
OlefinsUltra would give this refiner the flexibility to
further increase propylene yields while limiting dilu-
tion of the circulating catalyst inventory.
An additional consideration for this refiner was the
retention characteristics of the OlefinsUltra additive.
This refiner operates a power recovery train and,
naturally, they had to be sure that the additive would
not increase the load to the expander.
Following extensive pilot plant testing at their R&D
facilities, CEPSA La Rabida commenced additions of
OlefinsUltra in March, 2002. Key refinery data are
summarized in Figures 1-4.
Figures 1 and 2 show that, over a broad range of feed
UOP K factors, the selectivity of OlefinsUltra to
propylene is comparable to that of OlefinsMax on a
constant crystal basis and constant reactor tempera-
ture. The yield of propylene obtained was, as expect-
ed, comparable to that obtained with OlefinsMax;
however, only about sixty percent of the OlefinsUltra
additive was required. This clearly demonstrates
that the intrinsic activity of the ZSM-5 zeolite is
maintained at the very high levels contained in the
OlefinsUltra additive.
 Figure 1
OlefinsUltra Maintained Propylene Yield Above 14 vol% (8 wt%)
(Constant ZSM-5 Crystal Basis and Constant Reactor Temperature)

Figure 2
OlefinsUltra Propylene Selectivity Comparable to OlefinsMax on a
Constant ZSM-5 Crystal Basis and Constant Reactor Temperature

4
 Figure 3a
OlefinsUltra Increased Butylene Selectivity on a Constant ZSM-5 Crystal
Basis and Constant Reactor Temperature

Figure 3b

5
 Figure 4
OlefinsUltra Increased Iso-Butylene in the C4 Stream on a Constant
ZSM-5 Crystal Basis and Constant Reactor Temperature

Figures 3 and 4 summarize the impact of By switching to OlefinsUltra, a substantial reduction

OlefinsUltra on the yield of butylenes in this FCC
unit. On a constant ZSM-5 crystal basis,
OlefinsUltra increased the selectivity to butylenes
(Figure 3a and b) at constant LPG yield. The impact
on C4 olefinicity is shown in Figure 4. It should be
stressed that these data are at constant reactor tem-
perature and the incremental butylenes are obtained
over a range of feed UOP K factors. Indeed, the iso-
butylene content of the C4 stream was increased by
about 25% (relative).
The matrix employed in OlefinsUltra is unique to
this technology and it is believed that this may be a
key contributor in enhancing the butylene selectivity
in this particular commercial operation.
in the amount of ZSM-5 additive was needed to
achieve the desired level of propylene, enabling the
refiner to maintain the activity of the circulating cat-
alyst inventory with 10% lower fresh catalyst addi-
tions.
The commercial data presented above clearly demon-
strate the benefits of using ultra high activity ZSM-5
additives and, moreover, prove conclusively that all
the ZSM-5 crystal is fully utilized in such applica-
tions.

6
Conclusions
OlefinsUltra has been successfully commercialized
and is now being used in six refineries in North
America and Europe. In one application in Europe at
the CEPSA La Rabida refinery, OlefinsUltra enabled
the refiner to achieve very high yields of propylene
with substantially less additive, allowing the refiner
to reduce fresh catalyst addition rate. In addition,
OlefinsUltra showed enhanced butylene selectivity,
in this unit, enabling the refiner to increase feed-
stock to the alkylation unit.
OlefinsUltra is most suited to refiners that wish to
maximize the yield of light olefins, particularly
propylene, from the FCC unit that would otherwise
require high levels of less active additives, thus
avoiding dilution of the circulating catalyst invento-
ry and loss of conversion.
In the next few years, operators of FCC units will
look increasingly to the petrochemicals market to
boost their revenues by taking advantage of econom-
ic opportunities that arise in the propylene market.
OlefinsUltra will enable refiners to respond quickly
to these opportunities and take the production of
propylene in the FCC unit to a new level.
Acknowledgement
Davison Catalysts thanks CEPSA, La Rabida,
for permission to publish these data
7
References
1. S. Zinger, "Propylene: A By-Product, Co-Product,
or a Stand-Alone Product of the Future?", CMAI
2002 World Petrochemical Conference, San Antonio,
Texas, March 2002.
2. G. Harris, "Polypropylene – Taking the Rough
with the Smooth", CMAI 2002 World Petrochemical
Conference, San Antonio, Texas, March 2002.
3. J.T. Haley, "The FCC Unit’s Place in the
Worldwide Propylene Market", Catalagram, Number
88, 2002.
4. A. Pettman, "Global Ethylene – Long Term Trends
in a Key Base Feedstock", CMAI 2002 World
Petrochemical Conference, San Antonio, Texas,
March 2002.
5. S.W. Davey, J.T. Haley, and X. Zhao, "Propylene
Maximization with Grace Davison ZSM-5 Additive
Technology", Catalagram, Number 86, 1998.
6. S.W. Davey, J.T. Haley, X. Zhao, and B. Lakhanpal,
"Propylene Maximization with Grace Davison ZSM-5
Additive Technology", Grace Davison FCC
Technology Conference, Lisbon, Portugal, 1998.
7. J.R.D. Nee and G. Bourdillon, "OlefinsUltra™ -
Next Generation of Light Olefins Additives",
Catalagram Europe, November 2001.
 Davison Catalysts Clean Fuels
Technologies – A Commercial
Update
by
Jeffrey W. Balko
Marketing Manager, Clean Fuels Technologies,
Davison Catalysts
Clean fuels issues continue to dominate both time
and money requirements for refiners around the
world. In the area of Tier 2 gasoline sulfur, some
refiners have locked in their 30 ppm sulfur gasoline
plans, while many others have not decided on tech-
nologies. Some have even decided on technologies
and then recently changed their minds, due to high-
er than expected capital costs and new concerns
about actual performance levels. Many refiners still
have substantial time to make technology selections
and others are looking for ways to comply with the
first few years’ requirements through creative opera-
tions, thus delaying capital expenditures and giving
newer, less capital intensive technologies time to be
proven and further develop.
Shorter term clean fuels issues are playing heavily
on refiners’ minds as well. In California, the double
challenge of CARB III and MTBE phase-out will
have major implications on refining costs and poten-
tially on gasoline supplies as well. Elsewhere, the
new EPA conventional gasoline TAP (Toxic Air
Pollutant) specifications that commenced in January,
2002 are causing many refiners to incur extra pro-
cessing costs and to forego other processing opportu-
nities. Additionally, the clean fuels focus is not lim-
ited to the U.S. and Europe, as most other regions of
the world are making major fuel quality specifica-
tions changes as well.
8
Two of the key areas of concern for clean fuels pro-
duction are the level of olefins and sulfur in gasoline.
Since such a high percentage of the total gasoline
pool sulfur and olefins comes from FCC gasoline (up
to 90%), this stream is an obvious target. Many of
the options for controlling FCC gasoline sulfur and
olefins can be quite costly. These options include (but
are not limited to): reduced FCC feedstock flexibility;
reduced FCC gasoline endpoint; limitation on
amount of CARB/RFG gasoline that can be blended;
severe blending constraints for compliance with con-
ventional gasoline complex model requirements; and
very high severity of FCC feed and product treater
units.
For reasons mentioned above, refiners are increas-
ingly looking to novel FCC catalysts and additives as
an attractive alternative for controlling FCC gasoline
sulfur and olefins levels. Developing FCC catalyst
and additive technologies for the production of clean-
er FCC gasoline has been a key research and devel-
opment priority at Davison for more than ten years.1,2
Davison’s suite of current commercial clean fuels
FCC catalysts and additives are profiled below.
 Figure 5
Davison Catalysts Clean Fuels Technologies
Since the economic benefits of catalysts and addi-
tives for the production of cleaner FCC gasoline are
so large, one key variable for refiners to consider is
how well the materials will perform and, more pre-
cisely, the industry level of confidence in their per-
formance. While some other catalyst suppliers dis-
cuss interesting "possible mechanisms" and present
laboratory data or highly disguised commercial data,
Davison Catalysts is proud of the high degree of
industry satisfaction with the performance of its
technologies. This satisfaction is evidenced by ongo-
ing usage at many refineries as well as many refiner
co-authored papers and articles.2-9
9
Following this introduction are two brief articles
overviewing two refiners’ recent experiences with
Davison clean fuels catalyst technologies. The first
article overviews Tesoro’s successful application of
Davison’s RFG technology for gasoline olefins reduc-
tion. The second provides an update on a trial of
Davison’s Saturn technology at a Mid-Continent U.S.
refinery. While the final chapter on this Saturn
application has not been written (data analysis is
still underway), this brief article provides a status
report on the trial. Data through 50% changeout to
Saturn show similar sulfur reductions to the original
Saturn trial at Montana Refining.
An Application of
Davison’s RFG® Catalyst Technology in California
By Don Manuel, FCC Unit Manager, Tesoro Refining, Golden Eagle, CA
Richard Grove, Tech Service Engineer, Davison Catalysts, Houston, TX
Dave Sams, Ph.D., Account Manager, Davison Catalysts, San Francisco, CA

Since the introduction of California’s CARB clean
fuels program in 1996, a premium has been placed on
the reduction of gasoline olefins. This incentive will
increase next year when the new CARB-III rules
take effect. The personnel at Tesoro’s Golden Eagle
Refinery approached Davison in September of 2001
inquiring whether our RFG® technology would
reduce the olefin content of the FCC gasoline without
otherwise altering the yields.
Tesoro runs fully hydrotreated feed and operates
their FCC in full combustion. Their base catalyst
was a high matrix activity, high zeolite unit cell size
(~24.31 Å) version of an Orion catalyst that was
designed for maximum conversion and maximum
gasoline yield. In order to meet the objectives of con-
stant yields with a substantial reduction in gasoline
olefins, Davison formulated a custom RFG grade for
Tesoro. This catalyst was introduced earlier this
year and a 25% reduction in gasoline olefins relative
to the original baseline has been realized as shown in
Figure 6.
It is important to note that the current data was
obtained at a higher conversion level due to a combi-
nation of factors including catalyst impact and feed
quality. However, other key variables such as gaso-
line endpoint and riser temperature have remained
constant, confirming that the olefin reduction, when
compared at constant conversion, was due primarily
to the RFG technology.
Another important feature of Davison’s RFG technol-
ogy is the ability to minimize the impact on the over-
all base yields. For example, a modest octane loss of
less than 0.5% (relative basis) occurred as shown in
Figure 7. Additionally, the base amount of total LPG
olefins (propylene plus butylenes) and the gasoline
were preserved as illustrated in Figures 8 and 9.
With the move to MTBE free gasoline in California in
the 2003-2004 timeframe, many analysts and con-
sultants have projected a substantial (3-5%) shortfall
in gasoline supply. Although, there are many poten-

Figure 6
Gasoline Olefins versus Conversion

10
 Figure 7
Gasoline Octane Measured as (R+M)/2

tial mechanisms (imports, reduced consumption,
refinery capacity upgrades) for addressing this sup-
ply shortage, preserving/increasing FCC gasoline
yield, while reducing FCC gasoline olefin content,
will be very important.
Davison FCC catalysts can deliver substantial value
to refiners especially in the area of clean fuels pro-
duction. Based on the excellent olefin reduction per-
formance delivered by RFG technology, Tesoro con-
tinues to utilize this technology as they prepare for
CARB-III gasoline production.

Figure 8
Total LPG Olefins (Propylene Plus Butylenes)

11
 Figure 9
Gasoline Yield

Update: SaturnTM Trial at a Mid-Continent U.S. Refinery

Christopher Schult, Ph.D., Marketing Specialist, Davison Catalysts, Columbia, MD
Silas Wong, Technical Service Representative, Davison Catalysts, Houston, TX
Shahab Parva, Sales Representative, Davison Catalysts, Houston, TX

After a successful trial of Saturn at Montana
Refining Company9, numerous refiners approached
Davison concerning potential commercial trials of
Saturn. One of the first to voice an interest in apply-
ing Saturn as a means to meet Tier 2 sulfur reduc-
tion regulations was a mid-continent U.S. refinery.
The following brief article provides a status report on
this Saturn application. Note that the results pre-
sented here are only for a Saturn changeout
level of 30-50%. A more comprehensive analysis will
be provided in the future.
This mid-continent refiner operates a 20,000 bpd
UOP stack FCC unit. The FCC unit inventory is
approximately 150 tons of catalyst. The FCC feed is
hydrotreated and typical FCC feed sulfur levels are
0.55 - 0.6 wt%.
The objectives of the trial were to reduce FCC gaso-
line sulfur from 400-500 ppm to 75-100 ppm utilizing
the combination of following:
1. Obtain 60% sulfur reduction with Saturn
2. Increase Cat Feed Hydrotreater severity
(reduce 0.55-0.60 Feed S to 0.45)
3. Undercut gasoline by a maximum of 15°F.
Based on the outcome of the trial, the refiner would
decide how Saturn might fit into their Tier 2 gasoline
plans.
Base Case Conditions
Prior to the introduction of Saturn to the unit
(replacing a non-Davison base catalyst) samples of
the FCC gasoline were analyzed by GCAED for sul-
fur speciation. Approximately 60% of gasoline sulfur
was from species greater than and including ben-
zothiophene. This distribution was very similar to
the sulfur distribution previously seen in the trial at
Montana Refining. However, the samples were
taken during an operational period of lower than nor-
mal gasoline endpoint (415°F). After obtaining sam-
ples at the normal endpoint (430°F) the speciation
changed dramatically such that more than 75% of
the sulfur was benzothiophene and higher boiling
sulfur molecules. Since the heavier sulfur species
are more difficult to remove by catalytic methods we
would have projected 30-40 % reduction in this full
range FCC gasoline.

12
Results
Prior to the Saturn trial, the refiner identified two
other objectives beyond the primary goal of sulfur
reduction. The first was excellent catalyst retention
with a very low attrition rate. The second objective
was to maintain constant yields. These three issues,
sulfur reduction, retention, and yields would be
important in assessing the performance of Saturn.
Results of the sulfur reduction and yields are
detailed further in this paper, and in general, sulfur
reduction was on the order of 20-30% reduction at
only 30-50% turnover to Saturn, with minimal
impact on yields. Regarding catalyst retention,
Saturn was well retained in the unit. In fact, given
that prior operating experience has shown this unit
to be a very difficult service with respect to attrition,
Saturn retention was above the industry average.
Sulfur Reduction
Pilot Testing
With the many changes that can occur in a commer-
cial FCC unit, the best way to get a clear picture on
the sulfur reduction is to conduct pilot testing which
allows for an "apples-to-apples" comparison of the
operation. Pilot testing was conducted for three
equilibrium catalyst samples, a base case sample
(with no Saturn) and two samples with 30-37%
Figure 10
Pilot Testing of Equilibrium Catalyst
13
Saturn. All observations are for Saturn equilibrium
catalyst samples relative to base equilibrium catalyst.
At only a 30-50% changeout to Saturn, pilot testing
showed ~50% reduction in gasoline sulfur species
boiling less than benzothiophene (30% of commercial
gasoline sulfur), ~15% reduction for benzothiophene
(20% of commercial gasoline sulfur), and ~15%
reduction for alkylbenzothiophenes (50% of commer-
cial gasoline sulfur). For "full range" gasoline the
observed reduction was ~25%. A summary of the
sulfur reduction is presented in Figure 10.
GCAED Sulfur Speciation
In addition to pilot testing, detailed gasoline specia-
tion analysis was conducted to verify gasoline sulfur
reduction. During the trial, gasoline samples were
sent to the Davison laboratories for sulfur speciation
analysis by GCAED. Two comparisons were conduct-
ed, the first at 430°F gasoline endpoint and another
at a reduced endpoint of 415°F. Both analyses were
conducted using gasoline sulfur data normalized for
feed sulfur.
The first comparison at 430°F was for gasoline sam-
ples at 30-40% equilibrium catalyst changeover to
Saturn, refiner’s base case samples, and samples
from Montana Refining are presented in (Figure 11).
A 20% reduction in gasoline sulfur is observed
throughout the entire boiling range and 30-35%
reduction was demonstrated in the species less than
benzothiophene.
The second comparison at 415°F was for gasoline
samples at ~50 % changeover, and base case samples
at both 430°F and 415°F endpoints (see Figure 12).
When comparing at constant endpoint (415°F) a 27%
reduction in gasoline sulfur is observed throughout
the entire boiling range and 30% reduction was
demonstrated in the species less than benzothio-
phene. When comparing the 430°F base case to the
sample at 50% changeover (and 415°F) a 49% reduc-
tion in gasoline sulfur is observed throughout the
entire boiling range and 26% reduction was demon-
strated in the species less than benzothiophene.
Based on these results at Saturn changeout of 50% or
less, we would expect ~40% full range gasoline sulfur
reduction at full turnover to Saturn. Analysis of
samples at higher level of changeout to Saturn is
underway.
Yields
Pilot Testing
Based on results from pilot testing the following
results were observed for Saturn:
Figure 11
Comparison of Gasoline Speciation between
Mid-Continent U.S. Refiner and Montana Refining
14
1. The activity is similar to slightly higher (10-15%)
than base equilibrium catalyst
2. Coke yield was slightly higher (10-15%). From
previous commercial experience, pilot testing can
overstate impact of Saturn on coke yield and has not
been seen in the commercial unit.
3. Dry gas was down 5% to up 10% (relative).
4. Total LPG was unchanged to down 2%.
5. LPG olefins were unchanged to down very slightly.
6. Gasoline was unchanged to up 1.5%
7. Bottoms were unchanged to up 0.3%
Operating Data
Unit operating data were analyzed to verify the pilot
plant predictions. When compared on a constant
feed basis, unit data were consistent with the pilot
plant in that dry gas was up about 10% (relative,
LPG was down approximately 10% (relative), and
bottoms were up slightly. The one area of negative
impact was on octane. The base catalyst had an
equilibrated unit cell size of 24.28-24.29 Å, and
Saturn was expected to equilibrate at a similar cell
size. However, Saturn equilibrated to a unit cell size
in the 24.31-24.32 Å, which resulted in about a 1 to
1.5 octane number decrease. On an ongoing basis a
slight change could be made to the base Saturn for-
mulation to restore the decrease in octane.
 Figure 12
Effect of Saturn and Undercutting (15 °F) for Mid-Continent Refiner
Summary
The path toward meeting Tier 2 gasoline regulations
is extremely challenging for the refining industry.
Each refiner will have to develop a solution that bal-
ances profitability objectives with tolerance for risk.
Saturn represents an option for refiners looking to
minimize the capital and operating expense of meet-
ing Tier 2 regulations.
References:
1. R.H. Harding, R.R. Gatte, J.A. Whitecavage, and R.F.
Wormsbecher, in "205th ACS National Meeting", Denver,
1993.
2. J. Balko, R.H Harding, J. Nee, "FCC Catalyst
Technologies for Gasoline Sulphur Reduction", European
Catalyst Technology Conference 2000.
3. J. W. Balko, D. Podratz, J. A. Olesen, "Grace Davison
FCC Catalytic Technologies for Managing New Fuels
Regulations", 2000 NPRA Annual Meeting, AM-00-14.
15
4. R. K. Schiller, "Not Just Another GSR Success Story…",
Catalagram News, February 2002.
5. S. George, J. W. Balko, J. R. Riley, R. L. Grove, and M.
W. Zehender, "Commercialization of Davison’s New
Gasoline Sulfur Reduction Additive", Catalagram, No. 88,
2001.
6. J. L. Crisler, R. D. Lindley, C. H. Le, and J. Sorial,
"SuRCA Application at Premcor Refining, Hartford,
Illinois", Catalagram, No. 89, 2001.
7. S. Lang, E. J. Udvari, and D. A. Hunt, "SuRCA
Application at Frontier Refining’s Cheyenne Refinery",
Catalagram, No. 89, 2001.
8. D. A. Sams, "West Coast Refiner SuRCA Application",
Catalagram, No. 89, 2001.
9. S. K. Purnell, D. A. Hunt and D. Leach, “Catalytic
Reduction of Sulfur and Olefins in the FCCU: Commercial
Performance of Davison Catalyst and Additives for Clean
Fuels”, 2002 NPRA Annual Meeting, AM-02-37.
 Design for Six Sigma Leads to
Significant Advances
in Cat Feed Hydroprocessing

by
Charles W. Olsen, Ph. D.,
New Product Development Manager,
Advanced Refining Technologies

Introduction
As part of the Six Sigma program within Grace
Davison, Advanced Refining Technologies (ART)
researchers have received training in Design for Six
Sigma (DFSS). This program lays out a systematic
design methodology that includes as a key step iden-
tifying customer performance expectations. It
involves utilization of a common set of statistical
tools and methods to optimize quality, and teaches
scientists and engineers to design new products sta-
tistically. This is a disciplined approach to new prod-
uct development that requires a new design to pass
through several stages starting with a concept phase
where the voice of the customer is a critical input.
During the actual design phase various statistical
tools are used to work though product and process
steps, and risk is reduced through the use of Failure
Modes and Effects Analysis. Design of Experiments
is used to optimize the new development, and the
design capability is assessed through a variety of
pilot runs. The net result is a process geared towards
delivering the right products in a shorter time while
minimizing redesign. Applying this approach to Cat
Feed Hydroprocessing (CFH) has enabled ART to
develop a road map for state-of-the-art CFH cata-
lysts and catalyst systems.
Discussion
A key component to a high performance catalyst is
developing the right pore volume, surface area and
pore size distribution in the alumina support. As
Figure 13 clearly shows, when the pore size gets too
small (left hand side of the figure) activity for both
HDS and HDN falls off significantly. Catalysts in
this family typically have small pores and high sur-
face area suggesting a high number of active sites.
The majority of these sites, however, are inaccessible
due to diffusional limitations. A large percentage of
the active sites reside in pores that are too small to
allow the relatively large sulfur and nitrogen con-
taining molecules access. In addition, these sites are
quickly blocked off due to coking or pore mouth plug-
ging by poisons present in the feedstock. The net
effect is the number of useful active sites is fairly low.
Going to the right in Figure 13, on the other hand,
yields catalysts that have relatively large pores and
low surface area (i.e., low number of active sites).
Because of the large pore size, diffusional limitations
are reduced and the molecules of interest have ready
access to the active sites. In this case, however, the
number of active sites is low due to the low surface

16
 Figure 13
Impact of Pore Size on Catalyst Activity

area; the net effect is again that the number of use-
ful active sites is too low for the high activity
required.
The above discussion suggests that there is a region
that provides the best balance between reducing dif-
fusional limitations and increasing the number of
active sites. The use of Six Sigma has allowed ART to
define this region for Cat Feed Hydroprocessing.
Once the optimal region is known, Grace proprietary
alumina and forming technology are used to prepare
a catalyst support with the appropriate properties.
Figure 14 clearly shows that maximizing the number
of useful active sites in the appropriate region yields
significant increases in catalyst activity. ART AT575
has the highest concentration of useful active sites of
the catalyst tested, and consequently has the highest
activity.

Figure 14
Catalyst Activity Related to Sites in Optimum Range

17
 Figure 15
Optimum Metals Coverage Maximizes Catalyst Activity

Figure 16
Optimum Metals Composition Maximizes Catalyst Activity

With the required alumina support properties
defined, a set of designed experiments was under-
taken to determine the effects of metals coverage and
metals composition on catalyst performance. Figure
15 summarizes results showing how the metals cov-
erage effects activity. Not surprisingly, at low cover-
age the activity for both sulfur and nitrogen removal
is quite poor. Increasing the metals coverage rapid-
ly improves activity until an optimum coverage is
reached. Adding additional metals beyond that cov-
erage actually results in decreases in activity. This
is an indication that the metals carrying capacity of
the alumina support has been exceeded, and the
metals dispersion begins to decrease resulting in
lower activity. This is perhaps counter-intuitive as
it is usually thought that increasing metals coverage
is good for performance. This is indeed true up to a
certain coverage, but exceeding the optimum cover-
age is detrimental to catalytic performance.

18
 Figure 17
AT575 has Best HDS+HDN Activity for CFH

The metals composition is also a key catalyst proper-
ty greatly influencing activity. Figure 16 summa-
rizes results of an investigation looking at this cata-
lyst feature. Again, a volcano type plot is observed.
Like the metals coverage effects discussed above,
increasing the nickel coverage improves both HDS
and HDN activity by as much as 20-30%. Again, an
optimum coverage is observed and increasing nickel
coverage past that level results in decreasing per-
formance.
ART AT575 combines the optimum alumina support
properties with the best metals coverage and metals
composition indicated in Figures 13-16. The result-
ing performance puts it at the top of its class in Cat
Feed Hydroprocessing as indicated in Figure 17.
This figure summarizes the relative activity of sever-
al of the top catalysts used commercially for CFH.
AT575 has been put through extensive pilot testing
covering the range of process conditions typically
encountered in CFH. An experimental design was

Table II
Typical Pilot Results from AT575 Operating Variable Study

19
 Figure 18
AT775 and AT575 Compared to Commercial Trimetallic Catalysts
completed which investigated the effects of LHSV,
pressure and temperature on the activity of AT575
compared with two widely-used competitive catalysts
in CFH. The feed contains 30% heavy coker gas oil
and has a MABP of 790˚F. Table II contains some
additional feed properties and summarizes the activ-
ity differences for one set of conditions investigated.
AT575 clearly outperforms both catalysts for HDS
and HDN activity. The differences shown correspond
to about 5-10˚F activity advantage for AT575. Notice
also that AT575 provides greater product API
upgrade. This is an indication that AT575 has
improved PNA saturation activity relative to these
competitive products. The higher nitrogen removal
and PNA saturation activity of AT575 offer clear
benefits in terms of improved FCC feed quality
resulting in higher yields and superior quality prod-
ucts.
Another significant advancement for CFH resulting
from this program is ART AT775. This catalyst uti-
lizes the optimum support properties and metals
coverage defined above and is designed for even high-
er HDS activity through the addition of cobalt to the
metals composition. Figure 18 shows how the activ-
ity of AT775 and AT575 compare to two commercial-
ly available, trimetallic catalysts. The chart shows
that AT775 does indeed have superior HDS activity
20
compared to the other catalysts while at the same
time maintaining high HDN activity.
ART AT575 and AT775 form an integral part of
ART’s APART technology (Catalagram 88, 2001).
Briefly, APART technology utilizes tailored catalyst
systems designed to provide significant improve-
ments in CFH HDS while maintaining HDN and
other key performance attributes. As shown in
Figure 19, the APART system delivers superior
desulfurization activity without sacrificing nitrogen
removal or aromatics saturation activity. The figure
also shows that the FCC feed quality is maintained
relative to an all-NiMo loading; the constant coke
MAT conversion with APART is essentially the same
as that observed for the all-NiMo reference, and it
offers the added benefit of significantly lower FCC
feed sulfur and resulting lower FCC gasoline sulfur.
Another major benefit delivered by AT575, AT775
and associated APART systems is vastly improved
stability. Figure 20 shows some results highlighting
the performance of an APART system on an extreme-
ly tough DAO-containing feed. The feed has 15.5
API, 2.2 wt% sulfur and 20 ppm Ni+V. Upon intro-
ducing the feed, the APART system shows a 15˚F
advantage over the reference NiMo and this advan-
tage increases to about 30˚F over the course of the
 Figure 19
APART Systems Deliver Superior HDS and FCC Feed Quality

Figure 20
APART Systems Deliver Superior Tolerance to NI+V and Activity Retention

21
run; the APART system deactivates at less than 50%
of the rate of the reference catalyst. The significant-
ly improved stability is due in large part to the opti-
mized support properties and metals coverage dis-
cussed above.
Summary
ART has utilized DFSS tools to define the require-
ments of high activity cat feed hydroprocessing cata-
lysts. A key aspect is defining the right alumina car-
rier pore size distribution and balancing the tradeoff
between eliminating diffusional limitations, while
maximizing the number of active sites, thus, maxi-
mizing surface area. The goal is to maximize the
number of useful active sites, which in turn maxi-
mizes activity and stability. It is also critical to have
the appropriate metals coverage and metals compo-
sition in order to maximize activity.
sm
The refiner’s choice for
state-of-the-art information.
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22
These results have been combined with Grace pro-
prietary alumina and metals impregnation technolo-
gy to develop AT575 and AT775. AT575 offers
state-of-the-art performance in cat feed hydropro-
cessing applications where maximum FCC feed
quality is desired. AT775 offers extremely high HDS
activity with good HDN activity and is ideal for cases
where high desulfurization is required but hydrogen
is limited. High stability and metals (Ni+V) toler-
ance are built into both catalysts through the use of
the optimized support properties discussed above.
AT575 and AT775 are key components of APART cat-
alyst systems that are designed to offer highest HDS
activity while maintaining high FCC feed quality.
With these developments, ART is positioned to offer
refiners top tier performance in meeting their key
objectives, while at the same time accounting for unit
constraints.
 The Effects of Fe Poisoning
on FCC Catalysts:
An Update
by
George Yaluris, Ph. D., Senior Research Engineer,
Davison Catalysts

Presented at the
Grace Davison
Refining Technology Conference
Singapore
September, 2002

Despite the late recognition of the deleterious effects
of Fe on the FCC unit equilibrium catalyst properties
and performance, there is today a broad consensus
that excessive amounts of deposited Fe can result in
catalyst deactivation. Particulate Fe, commonly
referred to as tramp Fe, can come from a wide vari-
ety of sources, including Fe-rich soil contamination,
as well as tanks and other hardware corrosion.
Although it can raise coke and hydrogen, to the
extent that this form of inorganic Fe remains in rel-
atively large particles in the FCC unit, it is relative-
ly benign to the catalyst. However, inorganic Fe
which is finely dispersed or, worse, molecular Fe in
dissolved organic or inorganic compounds can have a
significant impact on catalyst performance and
result in catalyst deactivation. It should be realized,
that even tramp Fe can be damaging to the catalyst
if it attrites in the unit, resulting in fine Fe-rich dust
coating the FCC particles. While it is not known
what is the key particle size at which inorganic Fe
may start deactivating the catalyst, it is clear that
the smaller the particles the more the deposited Fe
will behave like organic Fe, and thus, the more
severe the catalyst deactivation will be.
The deactivation is manifested by loss of unit con-
version and bottoms cracking. Frequently in units
with high amounts of Fe, apparent bulk density
(ABD) decreases, possibly causing catalyst circula-
tion problems. Larger amounts of Fe can also be
responsible for increased SOx emissions, and even
make a unit operating in partial burn approach full
burn operation. The increase in SOx is attributed to
the ability of Fe to capture sulfur in the riser releas-
ing it in the regenerator as SOx. Similarly, Fe, when
present on the equilibrium catalyst in sufficient
amounts, can act as a promoter of CO oxidation
affecting the operation of partial burn units.
During Davison Catalysts’ 2000 Singapore Refining
Technology Conference, and later, at the 2001 NPRA
Annual Meeting, we presented the first comprehen-
sive mechanism of how Fe in combination with other
contaminant metals can affect catalyst, and thereby
unit performance1-3. We showed how Fe deposits on
the exterior surface of cracking catalyst particles,
and that in the form of reduced Fe oxides can com-
bine with silica and contaminant metals like Na and

23
Ca-forming low melting temperature phases. As the
catalyst ages in the unit, the formation of such phas-
es can result in accelerated sintering or melting that
destroys the pore structure of the exterior surface of
the particle. As a result, the exterior surface pores of
the particle are filled and closed preventing heavy
hydrocarbon molecules from reaching the largely
unaffected catalyst particle interior. Thus, Fe poi-
soning reduces unit conversion and bottoms cracking
activity. In our earlier work, we described how the
formation of low melting temperature phases and the
collapse of the exterior surface pore structure result
in the formation of nodules and valleys on the exteri-
or surface of the catalyst particle decreasing the
ABD and resulting in a glassy appearance. We also
showed why, due to its thermodynamic properties,
alumina does not form low temperature melting
phases with Fe or any other contaminant metals,
thus providing resistance to Fe poisoning.
The mechanism we proposed3 predicts that nodule
formation can occur on all catalysts, and the pres-
ence of nodules does not necessitate catalyst deacti-
vation. Indeed, in this paper, we will present addi-
tional evidence that nodules can form by a mecha-
nism which does not involve the formation of low
melting temperature phases. Thus, the presence of
nodules on the catalyst particles is a sign of possible
catalyst deactivation by Fe, but not a necessary and
sufficient condition of such deactivation.
Catalysts made with the proprietary Davison alumi-
na binding system (Al-Sol) were shown to be espe-
cially resistant to Fe poisoning. That is because this
active alumina binder is not susceptible to losing its
porosity due to Fe deactivation and is distributed
throughout the catalytic particle, protecting the cat-
alyst from Fe-induced deactivation. The Al-Sol bind-
ing system provides the ideal combination of the opti-
mum pore structure, allowing heavy hydrocarbon
molecules to readily diffuse into the particle interior,
and providing activity for bottoms cracking4. The
high resistance of Al-Sol catalysts to Fe has been
proven in units with the highest amounts of Fe in the
industry5,6, providing additional confirmation of our
experimental results and proposed mechanism.
Since the publication of our original work, others
have confirmed the role low-melting temperature
phases (also referred to as surface vitrification) play
on catalyst deactivation by Fe7. However, there
seems to be some dispute as to what these phases are
and the ability of alumina to retard their formation.
X-ray Photoelectron Spectroscopy (XPS), an extreme-
ly sensitive technique that measures surface concen-
tration five nm deep, clearly show that silica is inter-
mixed at the molecular level with the Fe, Ca, Ni and
24
other surface contaminants3. It is difficult to recon-
cile these data with the creation of low melting tem-
perature phases covering the catalytic particle sur-
face which do not include silica. On the other hand,
the XPS data show that alumina is covered by these
contaminants to a large degree and does not partici-
pate in the formation of such phases.
Thermodynamic analysis as well as lab studies1-3 and
field performance5,6 show that in the presence of alu-
mina low melting temperature phases cannot form,
but they can form on high silica catalysts.
Due to the difficulties of collecting equilibrium cata-
lyst samples without exposing them to air while hot,
it is not possible to know with confidence the oxida-
tion state or form of Fe in an FCC unit. It is also not
necessary that all Fe is available in reduced form to
react with silica. As the low melting temperature
phases of Fe with silica, Na and Ca begin to form con-
suming the reduced Fe present, more Fe2O3 can be
reduced as the catalyst circulates, and the vitrifica-
tion process can continue. In addition, while FeO
may be the most destructive form of Fe, Fe2O3 can
also lower the melting point of silica in the presence
of Na and Ca, enough to cause accelerated sintering
and pore closing, particularly when local hot spots on
the catalyst are taken into account. Our laboratory
studies1 show that at reducing FCC conditions Fe is
reduced at least to magnetite (Fe3O4). We should
note that magnetite is a mixed oxide at a 1:1 ratio of
Fe2O3 and FeO, and has a distinct X-Ray Diffraction
(XRD) pattern and properties.
Although we have made significant progress in
determining how Fe deactivates the FCC catalyst,
more work is needed. The goal of this paper is to dis-
cuss our recent work in this area and efforts to devel-
op catalyst deactivation protocols that allow us to
duplicate in the lab the effects of Fe on cracking cat-
alyst. In this paper we present evidence suggesting
an intriguing mechanism for how Fe, although
immobile at the molecular level in the FCC unit, can
readily migrate from one catalyst particle to another.
Furthermore, we present evidence suggesting that
consistent with our proposed mechanism, aging is a
factor in the catalyst developing signs of poisoning by
Fe. In addition, we show that it is possible to simu-
late in the lab the most important effects of Fe on
FCC catalyst performance. Finally, we demonstrate
that we can use our understanding of the chemistry
of Fe in the FCC unit to make Fe-resistant catalysts
that exhibit excellent performance in FCC units with
the highest Fe levels on equilibrium catalyst in the
industry.
 Figure 21
Distribution of Fe, Na, Ni and V on Equilibrium Catalyst Fractions

(from a unit with low to moderate amounts of Fe separated by a

Sink/Float method. Fe on Equilibrium Catalyst 0.74 wt.% as Fe2O3.)

Fe DEPOSITION AND CATALYST We examined the hypothesis of the non-uniform Fe

AGING IN THE FCC UNIT
The Distribution of Fe with Catalyst Age
Since Fe does not penetrate into the interior of FCC
catalyst particles1-3, we have concluded that it is not
a mobile species in the FCC unit regenerator.
Neither is Ca or Ni, although Ni can, under certain
circumstances, penetrate inside the particle.
However, Na and V are very mobile uniformly dis-
tributing throughout the particle. Based on these
results it is reasonable to expect that there is no
molecular mechanism that allows Fe to migrate from
particle to particle. Any such mechanism (gas phase
species or surface diffusion) would result not only in
Fe migrating from particle to particle, but also
migrating inside the catalyst particle like Na or V.
Thus, as the catalyst ages one expects more and
more Fe to accumulate on the older particles, result-
ing in a distribution of Fe with equilibrium catalyst
age that is non-uniform, with the oldest particles
having the highest Fe amount and the youngest par-
ticles having the lowest.
distribution with catalyst age by taking an equilibri-
um catalyst and separating it in eight separate age
fractions using a density separation method, com-
monly known as Sink/Float (S/F), described else-
where8. As long as the equilibrium catalyst does not
contain catalysts of different composition, i.e., it is
not a catalyst blend, we can reliably assume that the
heaviest fractions are the most aged, while the light-
est are the youngest. When we examine the distri-
bution of contaminant metals on an equilibrium cat-
alyst containing low to moderate amounts of deposit-
ed Fe, we see the expected profile (Figure 21). In
agreement with the results we reported earlier1-3, Fe
and Ni are the most immobile species, showing very
sharp, non-uniform distributions with catalyst age.
On the other hand, V and Na are more uniformly dis-
tributed. It is worth noting that, as expected, there
is less V on the youngest catalyst particles. In fact,
the V mobility from the oldest to the youngest parti-
cles depends on the V passivation properties of the
catalyst and unit design and operation. However,
the youngest particles have more Na. This is
because the youngest equilibrium catalyst particles

25
 Figure 22
Distribution of Fe, Ca, Na, Ni and V on Equilibrium Catalyst Fractions

(from a unit with high amounts of deposited Fe separated by a Sink/Float method. Fe and Ca on
Equilibrium Catalyst 1.91 wt.% as Fe2O3 and 0.15 wt.% as CaO.)

contain the highest amounts of zeolite with the
stronger acid sites. Thus, as Na tends to accumulate
on the catalyst with the stronger and highest num-
ber of acid sites, the youngest catalyst fraction will
have more Na than the older and largely deactivated
one.
When we conduct the same analysis of an equilibri-
um catalyst from one of the few units with very high
levels of Fe deposited on the catalyst, the Fe distri-
bution picture discussed above is reversed (Figure
22). Na and V remain more uniformly distributed
than Ni, with V concentrating on the oldest catalyst
particles, and Na concentrating on the youngest. Ni
and Ca have a non-uniform distribution, with the
oldest particles having the highest Ni and Ca con-
centration in the inventory and the youngest the low-
est. However, Fe appears to be relatively uniformly
distributed among the particles of different ages. In
fact, in this equilibrium catalyst, Fe distribution
appears to be more uniform than that of V.
The Mechanism of Fe Transport in the FCCU
Regenerator
A relatively uniform distribution of Fe on equilibri-
um catalyst has been reported before9. The authors
speculated that as Fe deposits, and the exterior sur-
face of the catalyst particles is deactivated, catalytic
cracking ceases on these particles stopping further
Fe deposition on the most aged particles of the inven-
tory. Cracking continues on the younger particles on
which Fe now deposits resulting in a relatively uni-
form distribution. However, this mechanism does
not explain the data presented here. In our high-Fe
case of Figure 23, unlike Fe, Ca and Ni have non-uni-
form distributions with catalyst age. This suggests
that Ca and Ni continue to accumulate on the oldest
equilibrium catalyst particles even though Fe depo-
sition according to the proposed mechanism has
stopped. It is hard to imagine how the oldest catalyst
particles have been deactivated to such a degree that
cracking of feed molecules carrying Fe has stopped,
but cracking of the feed molecules carrying Ni, Ca
and even V continues. In addition, even the youngest
fraction of the catalyst (10 wt.% of total equilibrium
catalyst) contains 75% of the Fe in the oldest equi-
librium catalyst fraction. These levels of Fe are all
very high and the youngest catalyst particles should
not be significantly more active for catalytic cracking
than the rest of the catalyst.
We believe that the data lend themselves to a much
more likely interpretation that is consistent with all
observations. Organic or inorganic Fe, that is very
finely dispersed/dissolved in the feed (particle size

26

Table III
Metal Contaminants in an FCC Feed
(before and after removal of particulate
contamination by filtration. Analysis of the
particulatecontamination is also included.)
about or below 1 mm), deposits on the catalyst parti-
cles forming Fe rings on the exterior surface as we
have described. These Fe species combine with sili-
ca, Na, Ca and perhaps other contaminants to form
low melting temperature phases and are immobile.
However, there is another mechanism of Fe deposi-
tion. Many feeds contain particulate Fe contamina-
tion. We show an example of such a feed in Table III
before and after it was filtered to remove the partic-
ulate contamination. With the exception of Ni and V,
the majority of the Fe, Na, Ca and other metals is in
the filtered particulate contamination. Many of the
particles in the feed are fine, or they may attrite after
entering the unit forming a fine, Fe-rich dust that
sticks to the FCC catalyst particles. Such dust can
also be generated by attrition of Fe-rich rings formed
on the FCC particles by deposition of organic Fe or
other known sources of tramp Fe. Once such dust is
present in the unit it can easily move from particle to
particle until it reacts with the catalyst surface to
form low melting temperature phases or is entrained
out of the unit with the catalyst fines. The result is
the easy migration of Fe from the older to the
younger particles via this particulate mechanism. As
some of the Fe-rich dust particles attach to equilibri-
um catalyst particles, large nodules rich in Fe form.
This mechanism of nodule formation is distinct from
the more destructive mechanism we described earli-
er. The effect of these Fe-rich particles is largely
localized to the area to which they are attached, leav-
ing most of the catalytic particle unaffected. The

Figure 23
Distribution of Fe, Ca, Ce, Ni, Si and V
Youngest Fraction, 1.6% Fe2O3 Oldest Fraction, 2.1% Fe2O3

(in the youngest and oldest fractions of a high-Fe equilibrium catalyst. The two fractions were
obtained using the Sink/Float density separation method.)

27
deleterious effects will increase the more numerous
and the smaller they become on the catalyst surface,
unless the catalyst is resistant to the formation of
low melting temperature phases.
To verify this mechanism of Fe transport in the FCC
unit regenerator we examined the fines composition
of 16 units with various amounts of Fe on equilibri-
um catalyst. The presence of Fe-rich fines in the unit
facilitating interparticle Fe transport would result in
unit fines enriched in Fe. We show the results in
Table IV. For high-Fe units, in virtually all cases, the
Fe composition of the fines was 2-3.5 times that of
the Fe content of the equilibrium catalyst itself.
There was only one case where the fines Fe concen-
tration was close to that of the equilibrium catalyst.
On the other hand, for moderate- to low-Fe units, the
ratio of Fe on fines versus that on equilibrium cata-
lyst never exceeds two, and in most cases is very
close to one. In fact, for two units (D and I), lowering
the Fe on equilibrium catalyst decreases the enrich-
Table IV
Enrichment of Fines in Fe
Compared to Fe Concentration
on Equilibrium Catalyst.
Fe is reported as wt % Fe.
28
ment ratio of the fines in Fe. These observations con-
firm the presence of fine Fe-rich particles in FCC
units and suggest that high-Fe units are much more
likely to have this form of particulate Fe present
than lower Fe units.
The Role of Aging in Catalyst Deactivation by Fe
It is reasonable to expect that the formation of low
melting temperature phases requiring solid state
mixing of silica with Fe, Na, Ca and possibly other
contaminants will be a rather slow process taking
hours or perhaps a few days. As we show in Figure
23, there are only small differences in the way Fe
deposits on both the youngest and oldest particles,
that is it deposits only on the surface and without
penetrating inside the particles. The data we show
in Figure 23 are by Electron Probe Micro Analyzer
(EPMA), a technique which can measure and present
in color-coded pictures the relative distribution of an
element across a polished section of a particle. In the
case of the equilibrium catalyst in Figure 23, the old-
est equilibrium catalyst particles do not have dra-
matically higher amount of Fe than the youngest
particles. It is interesting to note that, as we dis-
cussed earlier, Ni can penetrate inside the particles
of the equilibrium catalyst in Figure 23 despite the
particles having aged with high levels of Fe.
While the deposition profile of Fe does not change
with aging, as we show in Figure 24, Scanning
Electron Microscopy (SEM) data suggest that there
is much less Fe-induced aging and nodule formation
on the youngest particles than the oldest. Thus,
although there is plenty of Fe on the younger parti-
cles to cause nodule formation, on most of these par-
ticles nodules have not yet formed by any of the
mechanisms we have described. This result suggests
that in addition to Fe deposition, aging is necessary
for the symptoms of Fe deactivation to appear on the
equilibrium catalyst.
Simulating The Effects of Fe on
Cracking Catalyst in the Laboratory
Unlike the effects of V, Ni or even Na, simulating the
effects of Fe on catalyst performance has been very
difficult. The virtually "skin deep" effects of Fe make
many of the techniques typically used for FCC cata-
lyst characterization not applicable, because they
tend to characterize the bulk of the particles, or all
the surface area, rather than just the exterior parti-
cle surface. In our earlier work we were able to over-
come the latter difficulty by making catalysts that
 Figure 24
SEM Pictures of the Youngest and Oldest Fractions of a
High-Fe Equilibrium Catalyst
Youngest Fraction, 1.6% Fe2O3
The two fractions were obtained using
the Sink/Float density separation method.
have in the bulk the composition typically measured
on the surface of Fe-poisoned catalysts3. Using these
catalysts, we showed that high amounts of Fe have
dramatic effects on the surface area, crystallinity
and texture of FCC catalysts. We also demonstrated
that a glassy phase can form in catalysts made with
a silica binder. However, the same phase does not
form on catalysts made with an alumina binder.
The catalysts we used in this early work, although
realistic models of the surface composition of Fe-con-
taminated catalysts, were for the most part not rep-
resentative of an actual catalyst particle with Fe poi-
soning limited to the particle exterior surface.
Developing a protocol to deactivate FCC catalysts
with Fe so that they can be tested for yield effects
faces several obstacles. Fe can be deposited using a
cyclic metals impregnation/deposition method using
feeds enriched with an Fe-containing organometallic
compound. The difficulty is that such compounds
may be too small in size or decompose too readily at
the high temperatures of the experiment, resulting
in the wrong Fe deposition profile. Even if the Fe is
deposited correctly, it is, in general, time consuming
to replicate in the laboratory the phase changes
occurring on the catalyst external surface.
Accelerating these processes is theoretically possible.
However, while the sought after low melting temper-
atures may form when an accelerated deactivation
protocol is used, the time and conditions of the deac-
tivation may be insufficient to give rise to the surface
texture changes we typically observe on Fe-deacti-
vated equilibrium catalysts. Contaminants like Na
29
Oldest Fraction, 2.1% Fe2O3
and Ca also play a role and they must be included in
any attempt to replicate in the lab the effects of Fe in
the field.
Despite the challenges, we have been able to suc-
cessfully simulate Fe deactivation of cracking cata-
lysts in our laboratories by developing specialized
deactivation protocols for both small scale testing
(e.g., ACE, MAT), as well as pilot plant testing. Our
experimental protocol includes:
• Use of appropriate Fe, Ca, Na, Ni and V precur-
sors which can be dissolved in the feed to accel-
erate the deposition of metals and ensure that
each metal is deposited as it would in an FCC
unit:
• A cyclic metals deposition method, where the
metals-enriched feed is cracked on the catalyst,
and then the catalyst is regenerated with or
without added steam to remove the coke and
deposit the metals. This cyclic process is repeat-
ed as many times as necessary to deposit the
desired level of metals. For this purpose a cyclic
metals impregnation unit (CMI) or a pilot plant
like the Davison Circulating Riser (DCR) can be
used.
• Cyclic Propylene Steaming (CPS) deactivation of
the metallated catalyst. Because reduced Fe is
more destructive1-3, and we expect most of the Fe
in the unit to be somewhat reduced, we use the
partial burn CPS protocol10.
• Deactivation of reference catalysts using the
same protocol but without using Fe and Ca metal
precursors. This ensures that the reference cases
 will have similar activity as the Fe-deactivated
catalysts, but will not suffer the deleterious
effects of Fe.
•Activity and yields testing in the ACE unit or
DCR with a resid or other suitable heavy feed.
Fe Tolerance of Si-Sol Versus Al-Sol Catalysts
Using our newly developed protocol we compared the
effects of Fe on the performance of a Si-Sol catalyst
versus that of an Al-Sol. With the exception of the
reference catalysts that have no Fe, each catalyst
was CPS deactivated at 788˚C with 0.9 wt.% added
Fe, and about 1400 ppm Ni and 650 ppm V deposit-
ed using the CMI unit. We show selected properties
of the catalysts in Table V. The two catalysts have
different physicochemical properties, and as expect-
ed, differ in activity, coke selectivity and bottoms
cracking. However, we selected these catalysts to
ascertain the effects of Fe on each type of catalyst,
and not to compare the performance of the two spe-
cific catalysts against each other. EPMA analysis of
cross sections of the deactivated catalysts allow us to
obtain the relative concentration of a deposited metal
throughout the particle and evaluate the degree to
Table V
Properties of Si-Sol and Al-Sol Catalysts Deactivated with Fe
(using the CMI unit and the protocol developed by Davison Catalysts.)
30
which we achieved proper Fe deposition. Figure 25
shows that while in some particles Fe has achieved
deep penetration, for most of them the Fe distribu-
tion obtained is similar to that seen on equilibrium
catalysts. The catalysts were tested in the ACE unit
with a resid feed. The results we show in Figure 26
confirm that Al-Sol catalysts are more resistant to Fe
poisoning than Si-Sol catalysts. While adding 0.9
wt.% Fe to the Al-Sol catalyst has no effect on its bot-
toms cracking selectivity, adding the same amount of
Fe on the Si-Sol catalyst results in bottoms yield
increasing by 12%.
Fe Tolerance of Davison Al-Sol Versus Other High
Alumina Catalysts
Using the DCR to deposit the metals and deactivate
the catalysts with Fe has been proven even more suc-
cessful than the use of the CMI unit. We deactivat-
ed two high-alumina catalysts with similar physico-
chemical properties, one Davison Al-Sol, and one
from another supplier. In this experiment, to more
accurately reflect in-unit deactivation, we deactivat-
ed the catalysts with about 0.9 wt.% Fe, 3000 ppm
CaO, 4000 ppm Na2O, 2000 ppm Ni, and 3000 ppm V.
 Table VI
Properties of Two High-Alumina Catalysts Deactivated with Fe

(using the Davison protocol and the DCR for metals deposition.
Catalyst A is the Davison Al-Sol catalyst.)

Figure 25
Fe Distribution of Lab-Deactivated Si-Sol Catalyst

(using the CMI unit and the Fe deactivation protocol.)

31
 Figure 26
Effect of Fe on Bottoms Conversion of a Si-Sol
and an Al-Sol Catalyst Deactivated With and Without Fe.

Figure 27
Fe distribution on Lab-Deactivated Catalyst

(using the new Fe deactivation protocol and the DCR to deposit the metals)

32
 Table VII
Effects of Fe on the Activity and Yields of Two High-Alumina Catalysts

(Deactivated using the new experimental protocol for simulating Fe

deactivation and using the DCR to deposit the metals. Data are
interpolated at 6.5 wt% coke. Catalyst A is a Davison Al-Sol catalyst.)

The final partial burn CPS deactivation step was car-
ried out at 1420˚F. The Fe, Ca, Ni, Na and V deposi-
tion profiles as viewed by EPMA in Figure 27 for one
of the catalysts are virtually identical to those seen
in FCC equilibrium catalysts. As a result, in Table
VI there is little difference in the surface area, cell
size and activity of these catalysts from those of the
reference catalysts deactivated without Fe and Ca.
However, despite our ability to simulate the deposi-
tion of Fe and Ca on the exterior surface of the cata-
lyst particle, we were not able to reproduce the nod-
ule formation characteristic of in-unit catalyst deac-
tivation with Fe. This result is not unexpected con-
sidering the difficulty of simulating every aspect of
the formation of low melting temperature phases on
the catalyst surface.
between the two catalysts increases when they are
deactivated with Fe.
In-Unit Performance Al-Sol Davison
Catalysts
Davison Al-Sol catalysts have been used for years in
units with the highest Fe on equilibrium catalysts in
the industry5,6. This trend has continued demon-
strating the superior tolerance of these catalysts to
poisoning by Fe. Recent data from two units validate
our conclusion regarding both the mechanism by
which Fe deactivates FCC catalysts and the superior
tolerance to Fe poisoning of Al-Sol catalysts.

We tested all catalysts in the DCR with a resid feed.
The results show that catalysts made with the
Davison Al-Sol catalyst are more resistant to Fe poi-
soning than other high alumina catalysts (Table VII).
The Al-Sol catalyst loses only 1.9 abs.% conversion
versus 4.0 abs% for the other high alumina catalyst.
The bottoms yield increase of the competitor catalyst
due to Fe is also 3.5 times more than that of the
Davison Al-Sol catalyst. Much of the superior resist-
ance of the Al-Sol catalyst to conversion and bottoms
cracking loss is translated to improved gasoline
selectivity and the difference in gasoline selectivity
In-Unit Deactivation of Al-Sol Versus High Silica
Catalyst
Davison analyzed two equilibrium catalysts, both
with high Fe levels (Table VIII). While the two cata-
lysts are not from the same unit, they are from units
using similar high-Fe feeds and with similar catalyst
inventory age. EPMA analysis of the two equilibri-
um catalysts shows that the Fe is deposited in the
same manner on both equilibrium catalysts (Figure
28). The process of Fe deposition is not a function of
the catalyst used. However, SEM pictures demon-

33
 Table VIII
Properties of High-Fe Al-Sol and High-Silica Equilibrium Catalyst

Figure 28
Fe Distribution on Al-Sol and High-Silica Equilibrium Catalysts
Al-Sol Equilibrium Catalyst High-Silica Equilibrium Catalyst

34
strate that while as many as half of the Al-Sol parti-
cles show little or no nodules formation, the high sil-
ica catalyst shows signs of severe nodule formation
and Fe deactivation (Figure 29). Optical microscopy
pictures confirm the SEM data (Figure 30). While
the Al-Sol catalyst particles show some dark-brown
specs due to locally high concentration of Fe, they
show no signs of the formation of a glassy phase.
Clearly, the Fe on the Al-Sol catalyst surface has not
reacted to form any low melting temperature phases.
On the other hand, the high-silica catalyst particles
are shiny and indicate the formation of low melting
temperature phases. In fact, because Fe has reacted
with the silica on the surface, even after our oxida-
tion treatment to remove any coke, the catalyst
maintains its glassy appearance and the Fe is not
oxidized to the dark-brown Fe2O3 oxide. Clearly the
Fe on the high silica catalyst is in a form other than
that of Fe2O3, and it cannot be oxidized with a typi-
cal calcination treatment at 595˚C.
Al-Sol Catalyst Performance in a High Fe Unit
High alumina catalysts, and particularly catalysts
made with the Davison Al-Sol binding system, have
been proven to be highly resistant to Fe poisoning in
a number of different FCC units5,6. We present here
Figure 29
SEM Pictures of Al-Sol and High-Silica Equilibrium Catalysts
Al-Sol Equilibrium Catalyst
35
one recent example from a resid unit processing
about 35,000 b/d using an Al-Sol catalyst exhibiting
excellent resistant to deactivation by Fe. This unit
typically runs high to very high Fe levels on equilib-
rium catalyst, as well as high Ni and V, with signifi-
cant levels of Na. During the nine months we moni-
tored unit performance on a Davison Al-Sol catalyst,
Fe levels on equilibrium catalyst fluctuated between
0.9 and 1.3 wt.% Fe. As we show in Figure 31, dur-
ing the same period unit conversion, other than the
normal unit variation, remained unchanged.
Product yields did not show any negative effects due
to Fe. Figure 32 shows that slurry yield in particu-
lar did not increase as Fe on equilibrium catalyst
increased. In fact, it appears that slurry yield
decreases somewhat with increasing Fe. Slurry yield
is the most sensitive yield to Fe poisoning, and
increased slurry yield is the most frequent complaint
from units suffering from catalyst deactivation by Fe.
Thus, these unit data amply demonstrate the ability
of the Davison Al-Sol catalysts to resist the deleteri-
ous effects on catalytic performance of high levels of
Fe contamination.
Conclusions
Davison has undertaken a concerted research effort
to understand how Fe affects FCC catalysts, the
High-Silica Equilibrium Catalyst
 Figure 30
Optical Microscopy Pictures of Al-Sol and
High-Silica Equilibrium Catalysts
Al-Sol Equilibrium Catalyst High-Silica Equilibrium Catalyst

Figure 31
Unit Conversion Versus Fe on Equilibrium Catalyst

(Data from a high-Fe unit from a period of nine months during which the
unit was using a Davison Al-Sol catalyst.)

36
 Figure 32
Unit Slurry Yield Versus Fe on Equilibrium Catalyst
(Data from a high-Fe unit from a period of nine months during which the
unit was using a Davison Al-Sol catalyst.)
deactivation mechanism, and how catalysts can be
made resistant to Fe poisoning. It is now clear that
Fe deposits on the exterior surface of all catalysts
forming characteristic Fe-rich rings. This deposition
process is not a function of catalyst type, supplier, or
any catalyst property. Once the Fe is on the catalyst,
it can react with silica and other deposited contami-
nant metals like Na and Ca to form low melting tem-
perature phases. This process is driven by thermo-
dynamics and it depends on factors like catalyst sur-
face composition, time, local particle temperature,
and design and operation of the FCC unit.
Eventually, the process results in the formation of a
glassy phase, which causes sintering and pore clos-
ing (vitrification) and loss of activity and bottoms
cracking. During this process characteristic nodules
and valleys are formed on the catalyst particle sur-
face.
Alumina is the only species known to resist this deac-
tivation process. Alumina raises dramatically the
melting temperature of phases that can form in its
presence, thus preventing melting or accelerated sin-
tering, and preserving the catalyst particle pore
structure, activity and bottoms cracking. The
Davison proprietary Al-Sol matrix is the most effec-
tive form of alumina for Fe tolerance, because it is
dispersed throughout the catalytic particle; it pro-
37
vides the pore structure required for diffusion of the
heavy hydrocarbon molecules inside the particle for
cracking; it has active sites for bottoms cracking
activity; and its pore structure is not susceptible to
closing by Fe contamination.
Deposited Fe is a highly immobile species, particu-
larly after it reacts with the catalyst particle surface
to form new phases. However, if the Fe is in the form
of fine dust or it can be converted to such dust in the
unit by attrition, it can easily transfer from particle
to particle until it reacts with the catalyst surface, or
it is entrained out of the unit. Thus, it is likely to
observe by SEM Fe-rich nodules on any catalyst,
including high alumina Fe-resistant catalysts. The
presence of nodules on the catalyst surface does not
necessitate catalyst deactivation, unless the Fe in
them can react with the silica on the catalyst surface.
The smaller the particle size of the Fe-rich dust in
the unit, the more likely this form of Fe will have a
deleterious impact on catalyst performance.
However, when the catalyst is Al-Sol, the alumina
matrix does not react with the Fe, low melting tem-
perature phases do not form, and its pore structure
and activity remain intact.
Our continuous research on the effects of Fe has so
far only served to reaffirm our original conclusions as
to the strategy one should follow to mitigate the
effects of Fe in an FCC unit1-3. We summarize this
strategy below:
1.Establish that any catalyst performance
deterioration observed is indeed due to
rising Fe levels on the equilibrium catalyst.
2.If possible, try to reduce the Fe coming into
the unit by limiting feed contamination.
3.Reduce the Na and Ca content of the feed.
4.If possible, minimize the regenerator
temperature, and improve catalyst coke
selectivity.
5.Use an appropriately designed Fe resistant
Al-Sol catalyst.
38
References
1. G. Yaluris, "The Effects of Fe Contamination on FCC
Catalysts" Grace Davison Refining Technology Conference,
Singapore, August, 16-18, 2000.
2. G. Yaluris, “The Effects of Fe Poisoning on FCC
Catalysts”, Catalagram No. 87, 2000.
3. G. Yaluris, W.-C. Cheng, L.T. Boock, M. Peters, and L.J.
Hunt, "The Effects of Fe Poisoning on FCC Catalysts"
NPRA, AM-01-59, New Orleans 2001.
4. X. Zhao, W.-C. Cheng, and J. A. Rudesill, "FCC Bottoms
Cracking Mechanisms and Implications for Catalyst
Design for Resid Applications" NPRA, AM-02-53, San
Antonio 2002.
5. B. Niess, Bayernoil Raffineriegesellschaft mbH, Impact
of Fe on FCC Resid Processing in Hydroprocessing, Grace
Davison Refining Technology Conference, Singapore,
August 16-18, 2000.
6. K. Meder, J. Nee, and G. Yaluris, "Kristal Clear"
Hydrocarbon Processing, 7(3), 37 (2002)
7. W.S. Wieland and D. Chung, "Simulation of Fe
Contamination" Hydrocarbon Processing, 7(3), 55 (2002).
8. L. T. Boock, J. Deady, T.-F. Lim, and G. Yaluris, "New
Developments in FCC Catalyst Deactivation by Metals:
Metals Mobility and the Vanadium Mobility Index (VMI),"
in Proceedings, 7th International Symposium on Catalyst
Deactivation, Cancún, Mexico, October 1997, Studies on
Surface Science and Catalysis, 111, 367 (1997).
9. S. J. Yanik, "Using Laboratory Lessons to Maximize
Profitability" Petroleum Technology Quarterly, Summer
2001, p. 15.
10. L. T. Boock, T. F. Petti, and J. A. Rudesill, Ch 12,
Contaminant-Metal Deactivation and Metals
Dehydrogenation Effects During Cyclic Propylene
Steaming of Fluid Catalytic Cracking Catalysts in
Deactivation and Testing of Hydrocarbon Processing
Catalysts, P. O’Connor, T. Takatsuka, and G. Woolery Eds.,
ACS Symposium Series 634, Ch. 12, p. 171, Washington,
DC, 1996.
 Davison Catalysts Presents
Complete Additives Solutions
by
John T. Sorial
FCC Technical Service Representative
Davison Catalysts
Refiners today operate in a dynamic world economy,
which offers many challenges. These challenges
range from short-term spot market opportunities to
meeting stringent environmental regulations. In
such an environment the key to profitability is flexi-
bility. FCC additives are being used in greater quan-
tities to help refineries increase profits, meet product
specifications, and comply with government regula-
tions.
As part of a full service additive solution, Davison
Catalysts has worked on improving the concept of
the automated additive injection loader. Davison
Catalysts systems were designed in cooperation with
a leading supplier of dilute and dense phase pneu-
matic conveying equipment, and the result was the
development of an easy-to-use, reliable, state-of-the-
art injection system. Using the industry’s latest,
most advanced computer control and weighing tech-
nology, Davison loaders are fully automated and pro-
vide refiners continuous, exact additions from one
pound per day to ten tons per day or more. Davison
systems can operate as stand alone units (hopper
included) or connect to an existing silo.
Some of the features of the Davison Catalyst
Loaders are:
Davison Loaders state-of-the-art control panel
was designed for ease of use but still offers
maximum functionality. Some of the control
panel features are:
• Color graphic screen which displays injection
cycle, weight per injection, time to next
injection, actual weight per injection,
weight completed, and remaining weight for 24
hour period
• Trending charts for all loader functions.
• History screen which displays tabular form,
diagnostic information on the last 2,000
injections. Includes totals for daily and month
to date weights.
• Two-way DCS integration for remote operation
from an FCCU control room.
• On-screen alarm system for alerting refinery
personnel of system malfunctions.
All Davison injectors are pre-assembled, piped,
wired, and completely tested prior to shipment. The
only field connections required are a 2” air supply, 2”
conveying line (leading to the FCCU regenerator),
and 110 Volt electrical power supply.

• ASME certified pressure vessels stamped

with a national board number.
• One-piece welded mild steel structural
frame constructed with channels for unit
placement using a forklift.
• Replaceable internal filter cartridge to prevent
the discharge of fines to the atmosphere.
• Vacuum eductor for the transfer of catalyst
or additives from flow bins or drums.
• Suction hose with an integral grounding
wire and quick connect aluminum fittings.
• Allen Bradley control panel in a Nema 7/9
cast aluminum electrical enclosure for use
in Class 1 Division 1 environments. Control Panel from
Davison Catalysts Loader

39
Known throughout the industry for world-class tech-
nical service, Davison now offers that same level of
customer service for all Davison injection systems.
Davison’s loader team provides dedicated technical
service, which includes loader design, loader calibra-
tion, DCS installation and testing, operator training,
preventative maintenance and troubleshooting.
Davison Catalyst Systems full line of 1, 5, 10, 15, 20,
25 ton, and catalyst loaders offers refiners a full serv-
ice additive solution. Solutions that use Davison
Catalysts innovative additives and Davison injection
systems together, give refiners the increased flexibil-
ity they need in today’s market.

Catalyst Loader

40
Have you ever wished it were
this easy to remove sulfur?

With the products and expertise available

through Davison Catalysts and Advanced
Refining Technologies, our team now offers a
one-stop shop for clean fuels solutions. Davison
Catalysts pioneered technologies for gasoline
sulfur reduction in the FCCU over a decade ago.
Today, we offer the only commercially successful
products, D-PriSM™ and SuRCA™, which have
been used in over 30 units worldwide.

To meet today’s low sulfur diesel needs, refiners

can improve performance and reduce operating
costs with products like AT405, ART’s newest
hydrotreating catalyst. Innovative applications like
the SMART Catalyst System™ have been
developed to meet ULSD regulations of the future.

If you have questions about dealing with gasoline

or diesel regulations, the Davison Catalysts/ART
team has solutions.
information

@ W E B

E M A I L
www.gracedavison.com
catalysts@grace.com
 ©2002 W.R. Grace & Co.-Conn.

Davison Catalysts Davison Catalysts Grace GmbH & Co. K.G.

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7500 Grace Drive W.R. Grace Pte. Ltd. In der Hollerhecke 1
Columbia, MD 21044 501 Orchard Road Postfach 1445
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operating and use conditions vary and since we do not control such conditions, we must DISCLAIM ANY WARRANTY, EXPRESSED OR IMPLIED, with
regard to results to be obtained from the use of this product. Test methods are available on request.