ERTC 2025 Conference Newspaper

17 - 20 November 2025 Cannes, France

Official newspaper published by PTQ / Digital Refining

Hello and welcome! It is my pleasure to greet you at the 29th edition of the ERTC in the iconic Palais des Festivals et des Congrès in beauti- ful Cannes, France.

inside

European refiners reshaping fuels and petrochemicals strategies 3 Chemical recycling at scale for high-quality drop-in naphtha production 5 Novel textured sphere technology for new high-performance WGS catalysts 7 Turning iron contaminated feeds into profit: an effective approach to FCC catalyst protection 8 Solving key challenges facing European refiners 13

This year’s ERTC is set to be the biggest and best yet, as we continue to grow into a leading global platform, bringing together refiners from across the world for collabo- ration and knowledge sharing. We are proud to welcome a record num- ber of attendees and refiners representing more than 40 countries worldwide, along- side receipt of a record number of submis- sions for technical abstracts. In addition, I would like to express our gratitude to our Co-Host, TotalEnergies, for their support of ERTC 2025. A special thanks goes to the Advisory Board for their invaluable input and collaboration in curating an agenda that addresses the most pressing chal- lenges and opportunities in our industry. Over the next few days, our discussions will reflect the realities of Europe’s refin- ing sector – navigating today’s geopoliti- cal climate, balancing current operations with future transitions, boosting compet- itiveness, and fostering collaboration as essential steps toward shaping the indus- try’s future. At the World Refining Association, we remain committed to supporting your busi-

Vegan technology: low-carbon solution for renewable diesel and SAF

Electrification: transforming refining for a greener future 17 Closing the loop on catalyst waste: a circular vision for refining 19 From complexity to control: a new model for the digital refinery 21 Optimising renewable fuel feed- stock pretreatment 23 Applying RDT technology to reduce radial ΔT and extend run length24 Precious metals: real-world dynamics 27 Clean exhaust gas with extractive oxygen measurement 29 Benefits of high-throughput testing for firstand second-stage hydrocracking configurations 33 Reimagining the hydrocracker 34

content and key reflections on the down- stream sector in 2025. Enjoy the next few days!

ness, ensuring that Europe’s downstream industry stays competitive and thrives in an evolving landscape. We are pleased to welcome you, and we hope the coming days are filled with opportunities to cre- ate new contacts, catch up with indus- try peers, and engage with world-class

Matt Maginnis Global Managing Director World Refining Association

Advisory Board summary

Advocacy, Advocacy, Advocacy Industry collaboration is vital for resil- ience. Partnerships across the value chain can reduce costs and risks, while engag- ing external voices fosters broader under- standing. ERTC can be a platform for joint advocacy, reshaping public perception and influencing policy to support innovation and national security. Optimising Operations: The Key to Refining Sustainability and Competitiveness Efficiency and reliability remain critical. Incremental improvements and advanced technologies can boost margins, especially for smaller facilities. Optimising FCC units and addressing ageing infrastructure are priorities. The board seeks innovations in energy efficiency, process optimisation, and digital tools to strengthen resilience. This can deliver measurable impact and prepare assets for the evolving energy landscape.

Overcoming Barriers to AI Adoption and Talent Development Artificial intelligence offers major gains in refining, but adoption is slowed by cost and cultural barriers. It also helps attract talent seeking sustainability-driven roles. Building a culture of innovation and show- casing successful AI case studies at ERTC can position the industry as future-ready. The Latest Decarbonisation and Sustainability Strategies: Circular Economies, SAF, and Water Management Decarbonisation strategies face hurdles in green hydrogen, SAF mandates, and water scarcity. Refiners must embrace circular economy practices, including plastic recy- cling and CCUS. Blue hydrogen and tran- sitional technologies are essential bridges. The board seeks case studies on circular- ity, hydrogen, SAF, and sustainable water management to guide future action.

In preparation for ERTC 2025, we gath- ered leading executives for our annual Advisory Board meeting to delve into the key priorities, pressing challenges, and opportunities refiners are facing today. The board members shared their perspec- tives and strategies to strengthen collab- oration among companies. The discussion focused on the following key topics, which formed the basis of this year’s agenda: The Geopolitical Trilemma Europe’s refining sector faces declining fossil demand, tighter margins, and regula- tory uncertainty. To stay competitive, refin- ers must balance current operations with long-term emission goals. Strategic flexi- bility and reinvestment in adaptable assets are key, especially as global shifts, such as the potential changes to the US Inflation Reduction Act (IRA), create new opportuni- ties for leadership in clean technology.

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LARTC Ask the Experts

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ERTC 2025

European refiners reshaping fuels and petrochemicals strategies

Rene Gonzalez Editor, PTQ

Europe’s refining sector is being reshaped by three overlapping drivers. First, there is an accelerating regulatory push under the European Green Deal, which includes the Fit for 55 package, reforms to the EU Emissions Trading System (EU ETS), revi- sions to the FuelEU and Renewable Energy Directive (RED), and the forthcoming Carbon Border Adjustment Mechanism (CBAM). These measures are forcing refiners to cut carbon intensity, invest in cleaner feed- stocks, or face higher operating costs. The result is that refining output shrinks materi- ally under strict climate pathways. For exam- ple, Fit for 55 legally requires all sectors of the EU economy to reduce emissions by at least 55% by 2030, based on 1990 levels. Second, geopolitics, especially the Russia- Ukraine war and the resulting re-routing and sanctioning of hydrocarbon supplies, have tightened some supply channels, changed trade flows, and heightened energy security concerns that affect feedstock availability and logistics, according to the International Energy Agency (IEA). Third, market forces, including declining fossil fuel demand in the long run, stronger mandates for biofuels/sustainable avia- tion fuel (SAF), stagnating refining mar- gins in Europe, and global overcapacity, are prompting closures or conversions to alter- native fuels/chemical feedstocks. Compliance The EU Green Deal and the Fit for 55 pack- age raise the bar for greenhouse gas (GHG) emissions reductions and underpin reforms to the EU ETS, sector standards, and energy taxation, all of which increase compliance costs for energy-intensive industries such as refining. The EU ETS increases carbon expo- sure for refineries, while CBAM focuses on avoiding carbon leakage by charging import- ers for embedded emissions. According to information available from FuelsEurope, this means that European refiners pay higher carbon costs, but imports will also increas- ingly be subject to carbon pricing. The revised RED and FuelEU initiatives raise mandatory shares of renewables in transport fuels (including binders for SAF and advanced biofuels). These mandates create demand opportunities for hydro- treated esters and fatty acids (HEFA)/SAF and co-processing, as reflected in the pres- entations at this week’s ERTC 2025 in Cannes, France, which predict interest in technology advancements, raising capital, realignment of linked process assets, and permitting timeframes, among other factors ( Figure 1 ). Geopolitical forces With the Russia-Ukraine war and sanctions, European refiners have had to source alter- native crudes and manage logistical dis- ruption. The IEA has reported in detail how this has created short-term stress but also prompted strategic resilience planning,

HDO pathway products

~550 Nm/m (3,300 SCFB)

Octadecane

HDO

+16H

Docosane

Rapeseed oil

9c – Oleic acid

CO + H

HO + CO Reverse water-gas shift

CO + 3H

HO + CH Methanation

13c – Erucic acid

9c12c – Linoleic acid

+7H

Decarboxylation pathway products

Heptadecane

Decarboxylation

Heptadecane

~240 Nm/m3 (1,440 SCFB)

Henicosane

Figure 1 Fundamental HEFA chemistry. Source: SAF production via co-processing in the kerosene hydrotreater, Topsoe, PTQ Q2 2024

Market forces It is no secret that long-term oil demand growth is slowing in the Organisation for Economic Co-operation and Development (OECD) transportation fuels market due to electrification, efficiency gains, and modal shifts. IEA scenarios suggest that demand will plateau and evolve across fuel segments, with heavy-duty diesel remaining more resil- ient. This reduces the secular fuel volumes available to refiners in Europe and favours higher-value petrochemical feedstocks. Asia’s petrochemical sector remains a sig- nificant and growing naphtha consumer, as seen with the emergence of new naphtha-fed mega-steam crackers in China. According to a recent report from CHEMANALYST.com, concerns about unstable ethane and pro- pane supply from the US may have prompted China to double its naphtha import quota to 24 million tonnes. In fact, the IEA estimates that China’s naphtha demand will grow by 6% in 2025 and increase to 8.6% in 2026, providing arbitrage opportunities for European refineries still in operation. Against this backdrop, mandates for bio- fuels and SAF increase demand for renewa- ble feedstocks. This creates new markets for European refiners who are able to retrofit or co-process, while also intensifying competi- tion for feedstock oils (raising input costs). It is expected that the RED and FuelEU tra- jectory will point to materially higher biofuel demand by 2030. Regardless, European refining margins have been under pres- sure due to weaker demand, higher operat- ing and CO₂ costs, and global overcapacity, which has prompted closures, conversions to biorefineries or petrochemicals, and con- solidation. According to Insights Global, recent industry analyses have pointed to margin compression and a need for further rationalisation. Shifts in crude export patterns (lighter vs heavier grades) and changing discount

structures are affecting the economics of complex refineries (such as FCCs and coking units). Some plants are advantaged by flex- ibility, while others face costly conversions. A significant portion of available Capex will go toward abatement (carbon capture, uti- lisation, and storage), hydrogen readiness, co-processing units (such as HEFA and biorefining), and flexibility that allows pivot- ing to circular feedstocks or petrochemicals. In certain cases, deep integration with pet- rochemicals to capture higher margins may emerge; however, the conversion to biore- fineries and renewable diesel/SAF plants seems more realistic. Risk management Hedging, longer-term supply contracts, increased storage, and diversified crude sourcing will mitigate the impact of geopoliti- cal shocks. Compliance planning for the ETS and CBAM, along with supply chain tracea- bility for biofeedstocks, is an urgent priority, as discussed in this week’s ERTC presenta- tions and roundtables. Apparently, the refin- ing industry’s engagement with regulators on transition timelines, CBAM design, and realistic sustainability criteria for biofuels and SAF will influence competitiveness and investment certainty. Europe’s refining sector currently sits at an intersection of ambitious climate policy, disruptive geopolitics, and evolving market fundamentals. The net effect is accelerated structural change: lower crude throughput in Europe, higher compliance and capital costs, and new opportunities to redeploy assets toward biofuels, SAF, and petrochemicals. Refiners and their technology enablers who proactively invest in emissions abatement, feedstock flexibility, and new product lines, while managing geopolitical supply risk, will be best positioned for the energy transition.

Water

Ranate (Nonaromatics)

Water wash

Extract product to BTX fractionation

Extractor

Light nonaromatics

Feed

Solvent recovery column

Rich solvent

Steam

Extractive stripper

Lean solvent

including diversifying suppliers, using hub storage, and ensuring secure shipping lanes. Geopolitical forces have contributed to higher insurance costs, increased shipping expenses, and potential supply disruptions, all of which impact refinery margins. Global factors such as OPEC production strategies, US shale supply, and additional competition from emerging refinery cen- tres affect profitability and arbitrage oppor- tunities. For example, what is becoming of European refiners’ naphtha stream, which is typically targeted at gasoline produc- tion? Instead of shutting down gasoline-pro- ducing catalytic reformers, these refiners may find arbitrage opportunities by export- ing light naphtha to Asian ethylene produc- ers. Historically, a certain amount of their naphtha production has been necessary for producing jet and kerosene fuels. Even the heavy naphtha stream may become more bankable as an export product if aromat- ics demand increases (such as high-purity xylene, shown in Figure 2 ). Figure 2 Extractive distillation process. Source: Advances in distillation processes for BTX aromatics production, Kockler, D, Gas 2025

Contact: editor@petroleumtechnology.com

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ERTC 2025

Chemical recycling at scale for high-quality drop-in naphtha production

Milica Folić topsoe

The move toward a circular plastic economy requires the chemical recycling of mixed plastic waste so it can be turned into high- quality drop-in naphtha for steam crack- ers and new plastic products. Variability in waste composition and liquefaction meth- ods makes upgrading essential to ensure not only the drop-in naphtha quality for steam crackers, but also to absorb all the fluctuations in feedstock quality. One solution from Topsoe, PureStep™, has been developed through pilot tests of more than 60 various plastic pyrolysis oils, and delivers on-spec naphtha and heavier steam cracker feedstocks by combining advanced analysis, hydroprocessing expertise, and targeted contaminant removal. Already in commercial operation, it offers flexible solu- tions for diverse pyrolysis oils, helping turn plastic waste into valuable inputs for a more sustainable plastics value chain ( Figure 1 ). Chemical vs mechanical recycling of plastics Plastics can be recycled through two main routes: chemical and mechanical. Mechanical recycling is most effective when the waste stream is clean, sorted, and made up of a single polymer type, such as PET bottles. It can yield high-quality products with relatively low energy use, but repeated processing gradually reduces material per- formance, often resulting in ‘downcycling’ from food packaging to lower-value prod- ucts such as textiles or garden items. Chemical recycling is better suited for mixed or contaminated waste, including typical household packaging. By breaking down polymers and stripping away impu- rities, it produces feedstocks capable of making new plastics with virgin-level qual- ity, including those for food and pharma- ceutical applications. Processes such as pyrolysis and hydro- thermal liquefaction (HTL) thermochemi- cally convert solid plastic waste into plastic pyrolysis oils (PPOs), a liquid comparable in some ways to fossil feedstocks. However, PPOs contain significant levels of contami- nants (metals, halogens, and heteroatoms) that prevent direct use in steam crackers or fluid catalytic cracking (FCC) units without heavy dilution. Scaling chemical recycling and reducing dependence on virgin fossil carbon requires upgrading PPOs. Topsoe’s PureStep hydro- processing technology addresses this by removing contaminants and fine-tun- ing product properties, turning raw PPOs into high-quality steam cracker feedstock ( Figures 2 and 3 ). This bridges the qual- ity gap between pyrolysis oils and steam cracker feedstock, enabling higher recy- cling rates and supporting a robust circular plastics economy. PPOs are a growing feedstock opportunity PPOs are emerging as valuable feedstocks for refining and petrochemicals. Topsoe

Stabilisation section

Guard reactor

Main hydrotreating reactor

Conversion reactor

New plastic

FBP

Waste collection

Steam cracker

Metals

S Cl

Reactions:

Diene removal Styrene removal Light olen removal

P removal and metal removal (Si, As, Fe, etc.) Olen saturation

Halogen removal (Cl, Br, F) Sulphur removal Nitrogen removal Aromatic saturation Removal of halogens, nitrogen, sulphur, aromatics.

Hydrocracking Isomerisation

Conversion to liquid

PureStep™

Reduction of BP range, Improvement of cold ow properties.

Stabilise to avoid polymerisation reactions.

Pick up of metals and phosphorous.

Figure 1 Circular plastic economy with Topsoe’s PureStep technology

Figure 2 Technology ‘building blocks’ of PureStep

Detailed studies using scanning elec- tron microscopy reveal that conventional fossil catalysts tend to trap contaminants near the surface, leaving much of the cata- lyst unused. Topsoe’s advanced guard cata- lyst, developed specifically for PPOs, allows silicon and phosphorus to be absorbed throughout the entire catalyst structure, which increases overall capacity. This specialised catalyst also provides moderate hydrotreating activity, which is useful for removing nitrogen and chlorine and helps to limit coke formation that can deactivate the catalyst. Flexible options for upgrading PPOs PureStep technology provides adaptable methods for converting plastic pyrolysis oils into feedstock suitable for steam crack- ers. The process uses a combination of optional stabilisation, guard beds with cus- tom catalysts, hydrotreating, and optional hydrocracking, selected according to the feedstock’s properties and the desired product. Usually, at least two process steps are chosen to address the reactivity, contam- inants, and boiling range of PPOs. This approach supports a high proportion of recycled content in cracker feed and helps maintain the reliable operation of existing facilities. Expanding recycling with hydroprocessing Chemical recycling through pyrolysis is expected to play a significant part in the circular economy by supplying recycled feedstocks to current steam cracker units. Hydroprocessing is vital for expanding this value chain, as it can work with existing refinery equipment, allows for upgrades, and improves economics by enabling much greater volumes of PPOs to be used. Scaling up pyrolysis and reducing costs remain challenges, but progress is being made through collaboration across the industry and increased investment. As technologies develop and production vol- umes increase, hydroprocessing is posi- tioned to become a dependable method for circular plastic manufacturing.

began working with them in 2014, lever- aging decades of hydroprocessing experi- ence to meet rising demand for sustainable alternatives. While PPOs share traits with fossil and non-fossil feedstocks, they differ in key ways. They have a hydrogen content simi- lar to that of straight-run diesel, but contain more nitrogen and less sulphur. Compared to tyre-derived oil, PPOs are less aromatic and contain fewer impurities, which lowers hydrogen consumption during processing, delivering an economic and environmental advantage. Their manageable impurity lev- els and strong processing potential make PPOs an ideal candidate for customised upgrading solutions that align with circular economy goals and lower carbon intensity. Understanding feedstock variability PPOs contain many of the same contami- nants found in fossil-derived feedstocks, such as silicon, phosphorus, nitrogen, sul- phur, oxygen, and halogens, but in distinct molecular forms and concentrations. This difference stems from their origin: plastics carry additives and residual substances, such as stabilisers, flame retardants, adhe- sives, and other post-consumer waste components. As a result, traditional hydroprocessing methods require modification and fine-tun- ing to handle PPOs effectively. Developing catalysts specifically designed to address certain contaminants is critical. In some cases, PPOs also tend to polymerise, mak- ing early stabilisation (prior to hydrotreat- ing) necessary. Analytical testing can identify when this step is required. Optimising PPO processing demands a detailed understanding of its variability. This means collecting and evaluating sam- ples from a wide range of liquefaction tech- nologies and suppliers, and performing analysis at a molecular level to pinpoint spe- cific contaminant species, rather than rely- ing solely on bulk composition data. Producing naphtha from PPOs Compared with conventional naphtha feedstocks for steam crackers, PPOs pre- sent significant challenges. More than

Figure 3 Raw PPO and PureStep hydro- processed PPO

half of a typical PPO’s volume boils above 200°C – well beyond standard naphtha specifications – with heavy fractions often accounting for about 60% of the total. To meet boiling point limits, PureStep can incorporate hydrocracking to shift the dis- tillation profile downward. Contaminant distribution adds another layer of complexity. Fractionation studies have shown that silicon and chlorine are dispersed across the entire boiling range, from light naphtha to vacuum gas oil (VGO), rather than being confined to heavier cuts. Because even individual distillation frac- tions can hold 30-60% of the total silicon content and varying chlorine levels, sim- ple separation by fractionation is ineffec- tive. PureStep addresses this by combining deep contaminant removal with boiling point adjustment, enabling the entire PPO range to be converted into compliant steam cracker feedstock. This integrated approach ensures maximum utilisation of the feed and consistent product quality. Catalyst development for pyrolysis oils Fossil-based catalysts are sometimes applied to circular feedstocks such as plas- tic pyrolysis oils; however, custom-designed catalysts achieve much higher efficiency. Silicon and phosphorus contaminants found in PPOs have different sources compared to those in fossil or bio-based oils, which means tailored approaches are necessary.

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ERTC 2025

Novel textured sphere technology for new high-performance WGS catalysts

Emmanuel Iro, Richard Caulkin, Sergio A. Robledo, and Carl Keeley UNICAT Catalyst Technologies, LLC

Water-gas shift overview The water-gas shift (WGS) reaction max- imises hydrogen (H₂) yield by converting carbon monoxide (CO) to more hydrogen. This reaction can be represented as:

Shift catalyst overview

Temperature range (°C) Catalyst

Composition

Poisoning

Sintering

Magshift™

Traditional catalyst 1 Traditional catalyst 2 Traditional catalyst 3 Traditional catalyst 4

310 and 450

High-temperature shift

Typically contain iron oxide with chromium

Prone to deactivation by sulphur compounds

(HTS) catalysts

CO + H₂O ⇌ CO₂ + H₂

190 and 330

Medium-temperature shift (MTS) catalysts

Often contain a mix of

Sensitivity to sulphur

Susceptible to

copper, zinc, and alumina poisoning

sintering

Being an equilibrium reaction means the reaction can shift either to the products or to the reactants, depending on several fac- tors, such as temperature, pressure, vol- ume, the molar ratio of the feed, and the presence of a catalyst.¹ This reaction increases the total hydro- gen yield, making it a vital component of the hydrogen economy. Furthermore, removing carbon monoxide is crucial for many hydrogen applications, as it acts as a poison for many different catalyst sys- tems. 2 Depending on the operating condi- tions, several shift catalysts can be used ( Table 1 ). Description of the New Catalysts Traditional medium temperature shift (MTS) and low temperature shift (LTS) cat- alysts consist of copper oxide (CuO) dis- persed on a mixed support matrix of zinc oxide (ZnO) and alumina (Al₂O₃). The ZnO supports the CuO and inhibits copper crys- tallite sintering, maintaining stable cata- lyst activity. Similarly, alumina plays a crucial role in maintaining the dispersion of the active copper component, preventing sintering and enhancing thermal stabil- ity. Furthermore, alumina contributes to the overall surface area of the catalyst, improving the dispersion and providing more area for impregnating the active cop- per crystals, thereby ensuring sustained catalyst activity. Traditional catalysts are mainly formed by hydraulic pressing (tabletting). Tabletting results in a pore size distribution that biases towards micropore formation ( Figure 1 ), rendering a significant portion of the surface area and active copper inac- cessible due to diffusion limitations. Tabletting is commonly employed to impart mechanical strength to the cata- lyst particle. Carrier formulation develop- ment was conducted specifically for the WGS textured sphere catalyst. The pre- cise alumina particle size distribution within the supports has been meticulously engineered through experimental design to provide optimal physical and chemical properties tailored to the shift reaction. These properties include high cal- cined strength to enhance pellet mechanical integrity and hydrothermal stability, reduced pellet brittleness, improved Brunauer, Emmett and Teller (BET) surface area, and the necessary surface acidity. Furthermore, the shift catalyst carriers developed exhibit signifi-

150 to 250

Low-temperature shift

Usually based on a copper- Sensitivity to sulphur

Susceptible to

(LTS) catalysts

zinc oxide mix with a small amount of alumina

poisoning

sintering

Magshift™ MTS

Time on stream (h)

Table 1

Figure 2 Comparison of traditional MTS catalysts with Magshift MTS catalyst a

10 12 14 16

Magshift™ catalyst Traditional WGSR catalyst

0 2 4 6 8

Magshift™

Traditional catalyst 1 Traditional catalyst 2 Traditional catalyst 3 Traditional catalyst 4

Lab-produced Magshift™ LTS™

0.001

0.01

0.1

100

1000

Pore diameter, um

Time on stream (h)

Figure 1 Comparison of pore volume for traditional shift catalysts with Magshift

Figure 3 Comparison of traditional LTS catalysts with Magshift LTS catalyst b

cantly higher mean pore volume than tradi- tional shift catalysts. This pore volume has been designed within a specific size range to optimise the water-gas shift reaction (WGSR) performance (Figure 1). Therefore, the Magshift TM carrier tech- nology offers two primary advantages. The manufacturing method inherently pro- duces a robust matrix without necessitat- ing the compression of particles to achieve strength, thus incorporating mesopores and macropores that facilitate the utilisa- tion of the internal surface area. UNICAT’s research and development efforts successfully synthesised the cop- per-alumina-based textured sphere cat- alyst using its novel production method. This method enables copper to strongly interact with the alumina support, thereby eliminating the need for zinc or chromium promoters in the finished catalyst, which would otherwise compete for valuable surface area with the copper crystalline structure. This allows for better-dispersed, smaller copper crystals and enhanced resistance to thermal sintering. Additionally, the unique textured sphere shape reduces drag and enables reactants to contact a greater geometric surface area of the particle, thereby enabling a closer approach to equilibrium (ATE). Moreover, UNICAT can create the textured spheres in sizes ranging from 14mm to 32mm for WGS reactors. Such sizes are not feasible with traditional shift catalysts, which are limited to 3mm to 6mm cylindrical pellets, sometimes with holes or cut-outs.

copper sintering and extending the cata- lyst’s life-time-on-stream. A comparison of the pore structures of traditional shift catalysts and Magshift is shown in Figure 1. Magshift MTS In testing conducted at UNICAT’s pilot plant facilities in Dewsbury, UK, the Magshift MTS catalyst demonstrated per- formance comparable to commercially available catalysts. The hydrogen and CO₂ yields were consistent with those of com- petitive products. Under MTS test conditions, the tex- tured sphere catalyst exhibited slightly higher activity than the other catalysts (Traditional catalysts 2-4), consistently achieving 100% conversion throughout the test duration ( Figure 2 ). Traditional catalysts 2-4 also demon- strated high activity, achieving 97-98% conversion. However, Traditional catalyst 1 performed poorly at the elevated MTS test temperature of 300°C, with conver- sion rates ranging from 0.8% to 1.4%. This suboptimal performance could be attributed to the sintering of copper oxide under the pilot-plant test conditions. Magshift LTS In testing conducted at UNICAT’s pilot plant, the Magshift LTS catalyst dem- onstrated performance comparable to commercially available catalysts. All the catalysts were first heated under nitro-

did you know? the unique textured sphere shape reduces drag and enables reactants to contact a greater geometric surface area of the particle, thereby enabling a closer approach to equilibrium (ATE) Traditional WGS catalysts have more than 90% microporous structures. Suppose the supplier increases pellet sizes beyond 6mm to reduce pressure drop issues for its customers. In that case, the catalyst performance significantly deteriorates, as the reactant gases strug- gle to reach the active sites due to diffu- sion limitations. In contrast, Magshift has more than 70% macropores, allowing reactant gases to easily access all active sites. The exten- sive pore size network also facilitates the quick dissipation of formed products and heat from exothermic reactions, reducing

ERTC 2025

hot spots and enhances catalyst perfor- mance. Energy efficiency is also a bene- fit as Magshift catalyst reduces the need for high-pressure compressors or blow- ers. Pilot plant testing confirms that the new catalyst achieves high conversion rates, positioning it as a promising solu- tion for optimising hydrogen production and advancing a more sustainable energy future. Building upon this success, UNICAT is actively developing Magshift HTS for high- temperature shift applications, further expanding the potential of this innovative catalyst technology. Notes a All the catalysts were first heated under nitro- gen flow at 200°C for two hours to remove moisture. After the drying stage, hydrogen was introduced for catalyst reduction, under controlled conditions at 200°C for four hours. Subsequently, a feed comprising 20% CO in a carrier gas was introduced at a rate of 220 ml/

limitations, resulting in wasted surface area and active metal area. The resultant high pressure drop in reac- tors from the use of traditional WGS cat- alysts increases energy consumption for pumping and compressions. High pres- sure drop also leads to uneven flow dis- tribution and hot spots, which reduce catalyst effectiveness, leading to catalyst degradation. Magshift catalyst addresses these chal- lenges through its innovative textured sphere design and unique carrier technol- ogy, featuring a tailored pore size distri- bution that optimises the accessibility of active sites. The larger macropore struc- ture facilitates quick product and heat dissipation, reducing catalyst sintering, extending catalyst life, and improving efficiency. The benefits of switching to Magshift catalyst for WGS include improved flow dynamics, as reactant gases make bet- ter contact with catalyst, which eliminates

gen flow at 200°C for two hours to remove moisture. The hydrogen yields and CO₂ yields were consistent with those of com- petitive products. Except for Traditional catalyst 4, which exhibited lower catalytic activity (52-85% conversion), the other Traditional catalysts 1-3 demonstrated catalytic activity similar to the textured sphere catalyst (91-100% conversion) ( Figure 3 ). This indicates that even with only 16% CuO, the new catalyst compares favourably with the most active traditional LTS catalysts tested. Summary The WGS reaction is critical for enhancing hydrogen production and reducing carbon monoxide emissions in various industrial applications. Traditional WGS catalysts, while effective, face challenges such as causing high pressure drop in fixed-bed reactors due to their high attrition and small pellet sizes, temperature sensitivity, susceptibility to poisoning, and diffusion

min along with 0.88 ml/min of water over 90 ml of catalyst in an electrically heated reactor and maintained at 300°C. b After the drying stage, hydrogen was intro- duced for catalyst reduction, under con- trolled conditions at 200°C for four hours. Subsequently, a feed comprising 10% CO in a carrier gas was introduced at a rate of 220 ml/ min along with 0.5 ml/min of water over 90 ml of catalyst in an electrically heated reactor and maintained at 200°C. References 1 Baraj, E., Ciahotný, K. and Hlinčík, T., 2021, The water gas shift reaction: Catalysts and reaction mechanism, Fuel , 288, p.119817. 2 Palma, V., Ruocco, C., Martino, M., Meloni, E. and Ricca, A., 2017, Catalysts for the conver- sion of synthesis gas, Bioenergy systems for the future, Woodhead Publishing, pp.217-277. 3 Stuckey, M., 2023, A step change in cata- lyst development, Hydrocarbon Engineering Whitepaper: Catalyst Evolution.

Contact: paul.hudson@unicatcatalyst.com

Turning iron contaminated feeds into profit: an effective approach to FCC catalyst protection

Jeremy Mayol and Marie Goret-Rana JOhnson Matthey

ers to increase catalyst consumption and accept lower yields.

The rising availability of lower-value feed- stocks, such as oil sands and shale-derived crudes, offers refiners new, profitable opportunities. Yet, these unconventional crudes contain higher levels of metals, particularly iron, that create process- ing challenges. In fluid catalytic cracking (FCC) units, feed iron accumulates on the base catalyst, hindering cracking activ- ity, increasing coke and hydrogen produc- tion, and reducing fluidisation. The result is increased usage of base catalyst, lower process efficiency, and higher operating costs. With the right strategy, refiners can turn opportunity crudes into valuable products. This article outlines the impact of iron poi- soning, the limitations of conventional mitigation methods, and how Johnson Matthey’s CAT-AID TM metals trap addi- tive can effectively alleviate iron contam- ination. Mechanisms and a refinery case study are also presented. Impacts of iron poisoning Feed iron typically enters FCC units as porphyrins or naphthenates. Due to their size, these species are unable to diffuse into the internal structure of FCC cata- lyst particles. Instead, they preferentially deposit and accumulate on the catalyst surface. Over time, they form low-melting- point eutectics deposits or ‘iron nodules’. Their effects include: • Blocked pores and loss of catalyst activ- ity and conversion. • Erratic catalyst circulation due to reduced apparent bulk density. • Reduced liquefied petroleum gas (LPG) olefinicity from secondary reactions.

Conventional mitigation Traditional strategies include:

• Increased catalyst make-up or addition of purchased equilibrium catalyst (Ecat) to dilute iron. • Reformulated base catalyst with higher matrix content or iron-trapping functionality. • Reduced feed rate or higher metals feed to allow for easier operations on the unit. These provide partial relief but raise costs and seldom eliminate poisoning entirely. Higher catalyst addition rates often remain necessary,² which has spurred interest in metals trap additives.³ , ⁴ Fundamental insights into iron trapping Recent Johnson Matthey studies using high-resolution transmission electron microscopy (HR-TEM) and energy disper- sive spectroscopy (EDS) analysis of Ecat particles from commercial FCC units con- firmed that: • Iron concentrates on the outer 0.5-3 μm of catalyst particles.² • Deposits consist of 5-20 nm iron oxide nanoparticles in an amorphous iron-silica matrix. • The glassy iron–silica layer seals pores and blocks diffusion.² • Iron shows minimal mobility within parti- cles but can transfer between particles in the regenerator, most likely through colli- sions. Silica (especially from the Y-zeolite) plays a key role in this mobility, migrating under FCC regenerator conditions⁸ and promoting the growth of iron nodules.⁵ , ⁶ , ⁷

Figure 1 Scanning electron microscopy with energy-dispersive spectroscopy (SEM-EDS) mapping of Ecat showing the elemental distribution on the cross-section of particles including Ecat and CAT-AID additive. CAT-AID particles effectively trap iron and silica as evidenced by the rings on the surface. Vanadium rings on CAT-AID particles are clearly evi- dent, too (arrowed)

Figure 2 SEM images from Ecat samples before and after the addition of CAT-AID additive

(H₂S) in the riser and releasing it as SOx in the regenerator. Iron poisoning becomes significant above ~0.2 wt% added iron.¹ Unchecked, it reduces profitability by forcing refin-

• Increased coke and hydrogen yields as iron catalyses dehydrogenation. • Increased SOx emissions, since iron behaves like an inverse SOx reduction additive, capturing hydrogen sulphide

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ERTC 2025

These insights underpin the design of CAT-AID additive, a metals trap that cap- tures both iron and silica, preventing the formation of harmful nodules. How CAT-AID additive works CAT-AID additive is added at ~10% of the circulating inventory. Initially silica-free, it accumulates mobile silica in the regenera- tor. It is proposed that when an iron-con- taminated base catalyst particle collides with a CAT-AID particle, silica in the iron– silica layer reacts with magnesium in the additive to form stable magnesium sili- cate. This immobilises silica and captures iron on the additive surface ( Figure 1 ). The result is twofold: u Restored base catalyst activity by pre- venting new nodules and alleviating exist- ing poisoning. v Improved metal management overall, as CAT-AID additive also traps vanadium and contributes to SOx reduction. Microscopy confirms smoother Ecat surfaces and fewer nodules when CAT-AID additive is used. Figure 2 presents Ecat particles before and after the use of CAT- AID metals trap. Refinery case study An Asian refiner is processing a mixture of Arabian and local crudes. Its two-stage RFCC unit processes a mixture of light vacuum gas oil (VGO), coker gas oil (CGO), and heavy atmospheric residue (AR), and had relied on high fresh catalyst usage to manage metals. The refinery is primarily seeking to maximise high metals feed (AR) while increasing LPG and gasoline yields. CAT-AID additive was selected to manage metals contamination. Thanks to a sep- arate addition system, the additive was base-loaded to expedite the additive con- centration build-up in the circulating cata- lyst inventory, and then was evaluated at a steady-state concentration. Results included ( Table 1 ): • Increased usage of heavier feed. • Improved conversion at a similar riser severity despite heavier feed. • At a similar coke yield, the regenerator

Results of the CAT-AID additive trial

did you know? With targeted solutions like CAT-AID additive, refiners can mitigate iron poisoning, restore catalyst performance, and enhance profitability

w/o CAT-AID

w/CAT-AID 34.2/4,926

Delta

Feed rate (KBPD/TPD) Per cent heavy AR (%) Riser temp (F/°C) Regen 1 temp (F/°C) Regen 2 temp (F/°C) Delta coke regen 2 (wt%)

33.7/4,847

-+0.5/+79

42.0

46.7

+4.7

912/489

915/490 1,179/637 1,302/706

+3/+1

1,201/650 1,313/712

-22/-12

-11/-6 -0.03

0.68 71.0

0.65 72.2

Ecat activity (wt%)

+1.2 +207 +185 +3.7 -0.3 +1 .5 +2.6

Ecat V (ppm)

6,043 5,776

6,250 5,961

Ecat Fe 2

(ppm)

Conversion (wt%) Dry gas yield (wt%)

75.0

78.7

4.6 21.1

4.3

LPG yield (wt%)

22.6 44.2 15.3 6.0

Gasoline yield (wt%) LCO yield (wt%) Slurry yield (wt%)

41.6 18.4

-3.1

6.6

-0.6 -0.1

Coke yield (wt%)

7.7

7.6

Table 1

a mismatch from heaven, PTQ, May 2014 3 Todd Hochheiser, Yali Tang, Mehdi Allahverdi and Bart de Graaf, FCC addi- tive improves residue processing eco- nomics with high iron feeds, AFPM Annual Meeting, 2014 4 Adam Toenjes, Todd Hochheiser, Heather Blair, Setting the trap, Hydrocarbon Engineering, March 2019 5 Kalirai, U. Boesenberg, G. Falkenberg, F. Meirer, B.M. Weckhuysen, ChemCatChem 7 (2015) 3674–3682. X-ray Fluorescence Tomography of Aged Fluid-Catalytic- Cracking Catalyst Particles Reveals Insight into Metal Deposition Processes 6 Zhaoyong Liu, Zhongdong Zhang, Pusheng Liu, Jianing Zhai, and Chaohe Yang, “Iron Contamination Mechanism and Reaction Performance Research on FCC Catalyst” Journal of Nanotechnology, Volume 2015, Article ID 273859 7 J.M.M.; Sousa-Aguiar, E.F.; Aranda, D.A.G. “FCC Catalyst Accessibility – A review”, Catalysts 2023, 13, 784 8 Question 81: Under what conditions is iron on FCC catalyst mobile, and how does this affect catalyst performance? 2015 AFPM Q&A AND TECHNOLOGY FORUM

• Reduced SOx emissions, SOx reduction additive usage, and/or scrubber caustic soda consumption. • Improved Ecat circulation/fluidisation. Conclusions Metals-rich crudes present both risk and opportunity. Left unmanaged, iron con- tamination reduces catalyst efficiency and increases costs. With targeted solutions like CAT-AID additive, refiners can miti- gate iron poisoning, restore catalyst per- formance, and enhance profitability. Advances in characterisation techniques have revealed the mechanisms of iron dep- osition and mobility, enabling smarter, more effective additives. By combining fundamental science with proven commer- cial performance, refiners can confidently process lower-cost, high-iron crudes and unlock greater value. References 1 Zhu Yuxia, Du Quansheng, Lin Wei, Tang Liwen, Long Jun, Studies in Surface Science and Catalysis, Volume 166, 2007, Pages 201-212, “Studies of Iron Effects on FCC Catalysts” 2 Bart de Graaf, Yali Tang, Jeff Oberlin and Paul Diddams, Shale crudes and FCC:

temperature decreased. The new operat- ing window resulted from a reduction in delta-coke with CAT-AID additive. • Increased Ecat activity despite higher metals loading, enabling deeper cracking, leaving less coke on the spent catalyst for the same coke yield per feed. • Maximised gasoline and LPG yields, as per refinery objectives. Overall, the refinery realised an addi- tional $0.80 per barrel of feed margin, equating to ~$10M/year additional profit, net of CAT-AID additive cost. Broader benefits Beyond this case, CAT-AID additive gives refiners the flexibility to optimise opera- tions. By trapping iron and vanadium, it leads to more desirable reactions, lowering delta coke and enabling refiners to capture multiple benefits: • Increased feed rate and residue processing. • Lower regenerator temperature and improved heat balance. • Higher conversion, decreased H₂/dry gas. • Increased LPG olefinicity. • Lowered fresh and/or flushing Ecat addi- tion rates.

Contact: Marie.Goret-Rana@matthey.com

digitalrefining.com is the most extensive source of freely available information on all aspects of the refining, gas and petrochemical processing industries.

It provides a constantly growing database of technical articles, company literature, videos, industry news and events.

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05/04/2022 12:41:58

Industry Awards

19 November 2025 Cannes, France

OUR 2025 FINALISTS

REFINERY OF THE YEAR

CATALYST PRODUCER OF THE YEAR

DIGITAL TECHNOLOGY OF THE YEAR

ENERGY TRANSITION SOLUTION OF THE YEAR

DOWNSTREAM EXECUTIVE OF THE YEAR

Derek Becht Chief Operating Officer Entara

Martijn Arjen van Koten Executive Vice President Chemicals, Fuels & Feedstock OMV

Bernard Pinatel President Downstream and President Marketing & Services TotalEnergies

Ronald Doesburg Executive Vice President Galp

RISING STAR

Jessica Pawley Technical Sales Manager Johnson Matthey

Floriane Maldonado Lead Technology

László Szirmai Data & Contract Management Leader MOL Group

Engineer in Plastics Circular Economy Axens

For further information please contact: Elizabeth Cannon, Director | T: +44 207 384 3891 E: elizabeth.cannon@wraconferences.com

ERTC 2025

Solving key challenges facing European refiners

RENE Gonzalez editor, PTQ

conventional heavy fuel oils (HFO) to meet evolving policy requirements in the maritime sector. Failure to comply brings penalties, and fuel suppliers must ensure the availabil- ity of low-GHG and synthetic fuels, creating market opportunity for refiners to supply those fuels. International Maritime Organization (IMO) Net-zero Framework This year, the IMO committed to net zero GHG emissions from shipping by approx- imately 2050, requiring interim reduc- tions. New regulatory instruments under discussion include GHG intensity targets, fuel standards, and low or zero-carbon fuel adoption. This puts pressure across global supply chains, including refining and fuel production. Refineries must anticipate demand for lower-CI marine fuels, synthetic fuels, and fuel blends that meet both ship engine requirements and lifecycle emissions criteria. Ready-Now Technologies Proven technologies are now available for European refiners, and the Honeywell UOP refining portfolio is continually evolving to help refinery operations transition to sutain- able fuels. Worldwide, there are now 58 UOP Ecofining ® -powered units in the oper- ating, construction, or planning phases to efficiently convert waste bio-feedstocks into renewable diesel and SAF. This can help reduce GHG emissions relative to fossil fuels by up to 80%.¹ Key players in the refining industry are embracing the transformation. For exam- did you know? Honeywell UOP’s Biocrude Upgrading technology offers an effective pathway to produce drop-in biomarine fuel from biomass

The rising global demand for alternative fuels, such as sustainable aviation fuel (SAF), biodiesel, and renewable marine fuel, as well as shifting product slates, cost pres- sures, and the risk of stranded assets are all affecting profitability for European refin- ers. Additional concerns include Capex cost pressures, volatility in feedstock quality, and the need for digitisation to achieve bet- ter asset reliability and energy efficiency. Honeywell UOP has a long history of helping operators meet these challenges, and today it continues to expand its technology offer- ings to improve product quality and diversity, while also creating modular solutions that allow for faster deployment and scalability. Regulatory Pressures Existing refineries often need substantial retrofits for their hydrotreaters, processors, and co-processing units to handle renewable or synthetic feedstocks and produce fuels that meet new standards, while the demand for conventional fuels, such as gasoline and diesel, nears its expected peak. More than any other region, European refineries are operating in a fast-changing regulatory, economic, and technical envi- ronment. Among these, there are key policy frameworks that are raising both the risks and opportunities for operators:

Forest residue

Renewable gasoline

Renewable marine fuel

Energy crops

Honeywell UOP B iocrude U pgrading

Biocrude production

Sustainable aviation fuel

Agricultural residue

Figure 1 Biocrude Upgrading enables the production of SAF and biomarine fuel

ing carbon emissions by the end of the dec- ade. Waste wood and plant residues from agriculture, forestry, and other industries, known as lignocellulosic biomass, repre- sent a promising option for refiners as an abundant and relatively inexpensive renew- able fuel feedstock. Solutions like RTP from Honeywell make these feedstocks more accessible to refiners by converting them into liquid intermediates like pyoil. Honeywell UOP’s next-generation Biocrude Upgrading technology ( Figure 1 ) offers an effective pathway for refiners to access these biomass sources to produce drop-in biomarine fuel, which can signifi- cantly reduce lifecycle carbon emissions from conventional fossil-based engines ( Table 1 ). Biocrude Upgrading technology also ena- bles the production of SAF and renewable naphtha feed for gasoline production, giv- ing refiners and project developers multiple options to monetise biocrude intermediates derived from lignocellulosic biomass. Empowering refiners to Meet Compliance Targets European refiners are navigating a complex landscape shaped by rising global demand for renewable fuels, evolving regulatory frameworks, and mounting cost and opera- tional pressures. With tightening emissions standards under the EU ETS and ambitious mandates from ReFuelEU Aviation and FuelEU Maritime regulations, refiners must adapt quickly to avoid stranded assets and remain competitive. Honeywell UOP offers a robust suite of technologies that enable co-processing of renewable feedstocks, scalable deploy- ment, and significant reductions in car- bon intensity. These ready-now solutions empower refiners to meet compliance tar- gets, diversify product offerings, and sup- port the broader energy transition. References 1 GHG reductions are based on ICAO CORSIA default lifecycle emissions values for CORSIA- eligible fuels, Table 2 – Used Cooking Oil. http:// bit.ly/4gVT1Ej 2 Ecofining technology was developed and com- mercialised jointly by UOP in collaboration with ENI.

ple, energy leader ENI leveraged Ecofining² as part of a long-term strategy to grow its renewable fuels business by convert- ing its Gela refinery in Italy into a biorefin- ery. With a processing capacity of more than 400,000 MT/year, it is projected to produce almost a third of the expected European SAF demand in 2025. Solution Pathways As renewable fuel demand continues to grow, European refiners are exploring addi- tional renewable feedstocks to help meet regulatory requirements, transition to cleaner energy, and reduce operating costs to maintain margins. Honeywell UOP con- tinues to develop new process technologies to help achieve these goals. Honeywell UOP technologies like Ecofining, Co-processing, Fischer-Tropsch (FT) Unicracking ® , UOP eFining ® (methanol- to-jet), Ethanol-to-Jet (ETJ), and RTP (fast pyrolysis) processes enable the utilisation of a wide variety of feedstock sources for SAF, diesel, and other renewable fuels. In particular, SAF can be produced with a variety of sustainable feedstocks, including vegetable oils and inedible fats, low carbon intensity alcohols, and even synthesised fuels derived from captured CO₂ and hydro- gen (i.e. RFNBO). This represents an oppor- tunity for oil and gas organisations pursuing their own decarbonisation journeys to sup- port the aviation sector with fuels that can significantly reduce the environmental impact of flight. Policies such as FuelEU Maritime and the IMO Net-Zero Framework also represent a significant opportunity for refiners to meet new alternative fuel demands for maritime fleet operators, who need to begin reduc-

European Union Emissions Trading System (EU ETS)

The ETS places a rising cost on CO₂ and other greenhouse gas (GHG) emissions from stationary industrial sources (includ- ing refineries). The tightening of allow- ances, increasing carbon prices, and risk of carbon leakage all put pressure on margins. Refiners must find ways to reduce emis- sions intensity, both in process (such as fuel gas, steam, and hydrogen usage) and from feedstock, or face high compliance costs. ReFuelEU Aviation Regulation Part of the EU’s European Green Deal, known as the Fit for 55 Package, the ReFuelEU Aviation (Regulation (EU) 2023/2405) aims to increase the share of SAF sustainable aviation fuel at EU air- ports from a minimum of 2% in 2025 to 70% by 2050, with an additional sub-tar- get for renewable fuels of non-biological origin (RFNBO) of 1.2% by 2030 and 35% by 2050. FuelEU Maritime Regulation Also part of the Fit for 55 Package, the FuelEU Maritime (Regulation (EU) 2023/1805) introduces a requirement for ships above 5,000 gross tonnage calling at EU ports to use fuels with GHG intensity, on a Well-to-Wake (WtW) basis, which is gradu- ally reduced, starting with a small percent- age in 2025 and reaching much steeper cuts by 2050. In view of these challenges, maritime fleet operators are seeking alter- natives with lower carbon intensity (CI) than

Biomarine fuel advantages

Marine fuel alternatives

Biocrude fuel advantages

• Compatible with existing vessel configurations, bunkering and fuelling infrastructures

Alternative fossil fuels

• Additional CI reduction compared to LNG

(LNG and LPG)

• Lower-cost, abundant feedstock • Comparable production cost

Biofuels

(FANE and UCOME biodiesels or HVO renewable diesel)

• Compatible with existing vessel configurations, bunkering and fuelling infrastructure • Lower production cost • Safety considerations similar to traditional fuels which are well understood

E-fuels

(e-ammonia, e-methanol)

Contact: RenewableFuels@Honeywell.com

Table 1

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