Catalysis 2026 Issue

More accessible (mesoporous) zeolites alleviate such lim- itations and sizably enhance the yield to olefins in cracking reactions, as well as boost catalyst lifetime and olefin selec - tivity in methanol conversions. Hence, the use of premium zeolite catalysts can play a large role in the cost-effective shift of refineries away from fuels and towards chemicals such as (poly)olefins. Of course, such premium zeolite per - formance only makes sense if these zeolites can be scaled cost-effectively. Q What hydrogen production and recovery strategies are needed for expanded hydroprocessing operations? A Jumal Shah, Hydrogen Market Manager, Jumal.shah@ matthey.com, and Paul Clark, Digital Transformation Director, Catalyst Technologies, paul.clark@matthey.com, Johnson Matthey As hydroprocessing capacity expands, hydrogen demand rises sharply, requiring refiners to adopt integrated strat - egies for both production and recovery. Steam methane reforming (SMR) remains the dominant technology for on- site production. The ability of a hydrogen production unit to increase production rate is dependent on the bottlenecks of the plant. facilitates the creation of niche premium fuels, such as XP100 (100 RON gasoline), enabling Indian refiners to cater to high-performance segments while maximising refinery flexibility. In the current E20 ethanol blending scenario (EBMS), Octamax enhances octane levels in gasoline without increasing oxygen content. This ensures compliance with renewable Generally, increasing rates by up to 5% may be possible by changing to higher-performance catalysts and opti - mising operating conditions. Where hydrogen demand has increased by up to 20%, a revamp of the hydrogen plant may be necessary to consider options such as pre- reformers, structured SMR catalysts, new reformer tubes type, gas-heated reformers, and additional pressure swing adsorption beds. For larger-scale changes in hydrogen demand, sites will need to consider the addition of a new hydrogen produc - tion unit. Decarbonisation goals and local policies drive the requirements to consider sustainable solutions. In regions with an abundant source of low-cost natural gas and strin - gent legislation, hydrogen production with carbon cap - ture and storage (CCS) is an option. Newer flowsheets are increasing based on autothermal reformers (ATR), because the produced CO₂ is at process pressure and no flue gas is generated like in an SMR-based flowsheet. The testing results show that while octane loss remains unavoidable when meeting lower sulphur targets, OctaMax improves desulphurisation activity, enabling refiners to achieve these targets at lower operating temperatures. By operating at lower temperatures, OctaMax could result in longer cycle lengths while also reducing energy demand and associated CO₂ emissions. At the same time, its ability to preserve octane protects refinery profits, while the use of regenerated catalysts supports broader sustainability goals. This makes CO₂ more cost-effective to remove and cap - ture. Meanwhile, electrolysis powered by renewable energy is also emerging as a viable option for producing green hydrogen on a smaller scale, particularly where low-cost renewable electricity is available. Optimising these systems and designing hydroprocessing units to minimise purge losses can significantly cut operating costs and improve sustainability. Beyond hardware, digital solutions are playing a growing role. AI-driven hydrogen network management and digital twins allow real-time optimisation of supply and demand across multiple units, while predictive analytics help forecast consumption and prevent bottlenecks. Ultimately, a com - bination of low-carbon production technologies, advanced recovery systems, and smart process optimisation will be key to meeting rising hydrogen requirements while control - ling emissions and costs. Evonik Ryan Seyler and Dan Miskin Contact : ryan.seyler@evonik.com Henry Z Kister is a Fluor Corp. Senior Fellow and Director of Fractionation Technology. He has more than 35 years of experience in design, trou- bleshooting, revamping, field consulting, control, and start-up of frac - tionation processes and equipment. He has authored three books, the Distillation Equipment chapter in Perry’s Handbook , and about 150 articles. He has taught the IChemE-sponsored Practical Distillation Technology course more than 550 times in 26 countries, and a recent Troubleshooting Distillation Controls course, also sponsored by IChemE. A recipient of several awards, he obtained BE and ME degrees from the University of NSW in Australia. He has been serving on the FRI Technical Advisory and Design Practices Committees for more than 25 years. talarir@indianoil.in Satyen Kumar Das dassk5@indianoil.in R K Kaushik Singha kaushik_singha@indianoil.in Alok Sharma sharmaa@indianoil.in to fresh catalyst while delivering cost savings through extended cycle lengths and reduced changeout needs, with the added benefit of lowering landfill waste, reducing demand for mined raw materials, and improving the over - all lifecycle footprint of refining operations – all without sacrificing fuel quality. Final thoughts By operating at lower temperatures, OctaMax could result in longer cycle lengths while also reducing energy demand and associated CO₂ emissions Daniel Hussman is a Senior Process Engineer at the Parkland Burnaby Refinery in Burnaby, BC Canada, responsible for process improvement and yield optimisation of a crude distillation unit, as well as the entire naphtha and diesel blocks. He has more than 15 years of experience in process troubleshooting, debottlenecking, solution implementation, risk management, and reliability improvement. He has authored four technical publications and is a member of the Canadian Crude Quality Technical Association. He holds a BSc in chemical engineering and an MSc in transport phenomena and separation processes from Ferdowsi University of Mashhad, Iran. environmental specifications using a specific regenerated catalyst without additional octane penalties compared to fresh alternatives. For markets where the price spread between low- and high-octane gasoline is significant, this selectivity provides direct commercial benefits. Regeneration and sustainability Historically, regenerated catalysts have rarely been con - sidered for FCC gasoline HDS because of the demanding selectivity requirements. OctaMax overcomes this limita - tion by combining tailored regeneration techniques with optimised formulations for uniquely selected CoMo cata - lysts. Testing confirmed that regenerated OctaMax deliv - ers improved activity while matching the octane selectivity of existing alternatives. This advance opens the door for refiners to take advan - tage of the reduced cost and sustainability benefits of catalyst reuse in FCC gasoline HDS units. For example, catalyst reuse offers a significantly lower-cost alternative Conclusion Octamax is an innovative solution for producing BS-VI-compliant regular and premium gasoline. By converting low-value cracked C₄ streams, traditionally routed to the LPG pool, into an oxygen-free, high-octane, olefin-rich product, it enables direct blending into the gasoline pool, subject to olefin content constraints. With a high BRON, it provides a significant octane buffer, allowing refiners to upgrade low-RON naphtha, which not only enhances gasoline volume but also offers a tangible opportunity to improve GRMs. Octamax boosts production capacity and ethanol blending targets and sustainability goals while maintaining fuel quality standards. The technology expands the base gasoline pool and allows for maximum ethanol blending, making it a strategic enabler for refiners in producing compliant and economically viable gasoline blends. Following its success at Mathura Refinery, two grassroots units of capacity 110 kTA and 102 kTA are in the advanced stage of implementation in India, with scheduled commissioning by 2026. Abdullah Abufara is a process engineer at the Parkland Burnaby Refinery, with significant knowledge and experience in producing renewable fuels and co-processing biofeedstocks in diesel hydrotreating and FCC units. He holds a BSc from the American University of Sharjah, UAE, and an MSc from the University of Saskatchewan, Canada. As global specifications tighten and competitive pres - sures grow, technologies that align compliance, per - formance, and sustainability will become increasingly essential. Octane has long been a key measure of fuel quality, and it remains an important factor for refiners as they navigate the balance between environmental compli - ance and commercial performance. Josh Donohue is a process engineer at the Parkland Burnaby Refinery, supporting the Splitter (crude), naphtha and distillate hydrotreating, and catalytic reforming units. He has three years of experience in the oil and gas industry and obtained a BSc in chemical engineering with distinc- tion from the University of Western Ontario, Canada. Prosenjit Maji majip@indianoil.in Pushkar Varshney varshneyp@indianoil.in Talari Raju Komi Chandi is a senior process engineer at the Parkland Burnaby Refinery, and has worked on several refinery technologies. He has held various roles in process engineering, including process troubleshooting and debottlenecking. This article is based on a presentation at The Distillation Symposium of the AIChE Meeting, Houston, TX, Spring 2023. References 1 Kister H Z, P M Mathias, D E Steinmeyer, W R Penney, V S Monical, J R Fair, Equipment for distillation, gas absorption, phase dispersion and phase separation, in D W Green and R H Perry Perry’s Chemical Engineers’ Handbook 9th Ed., Sec 14, McGraw Hill, New York, 2018. 2 Kister H Z, Use Quantitative gamma scans to troubleshoot maldistri- bution on trays, Chem. Eng. Progr. , February 2013. 3 Harrison M E, Gamma scan evaluation for distillation column debottle- necking, Chem. Eng. Prog. 86 (3), pp.37-44, March 1990. 4 Kister H Z, Is the Hydraulic Gradient on Sieve and Valve trays Negligible? Paper presented at the Topical Conference on Distillation, AIChE Meeting, Houston, Texas, 2012. 5 Kister H Z, M Olsson, An investigation of premature flooding in a dis - tillation column, Chem. Eng. , p.29, January 2019. 6 Wang W, A P Watkinson, Iron Sulphide and Coke Fouling from Sour Oils: Review and Initial Parameters , Proceedings of International Conference on Heat Exchanger Fouling and Cleaning 2011 Crete Island, Greece, June 5-10, 2011. Gordon Bruce is the Manager of Blending and Shipping Operations at the Parkland Burnaby Refinery. With 20 years of experience, he has held roles in process engineering, production supply, and turnaround operations. He holds a Bachelor of chemical engineering from Dalhousie University in Halifax NS.

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Resiliency of fossil-based feedstocks … Catalysis Q&A ... Incorporating new technology and tools for catalyst development … FCC co-processing of biogenic and recyclable feedstocks: Part I … Passivating vanadium in FCC operations … Hybrid catalyst loading reduces fill cost and carbon footprint … Catalyst rejuvenation offers circular solution for hydroprocessing catalysts … Catalyst technology for maximum light olefins and ultra-low emissions … Experimental study on diesel fuel haziness … Troubleshooting low or high regenerator temperatures … Zeopore is making its mark in green applications through zeolite modification. Q1 2024 Issue of PTQ

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