PTQ Q2 2026 Issue

Breaking iron barrier when processing heavy/unconventional FCC feedstocks

Technical analysis of an advanced FCC catalyst showed significant yield improvements and increased VTB processing capacity with Fe-contaminated FCC feedstocks

Scott Barton, Deependra Parmar, Eswar Iyyamperumal, and Manuela Beatriz-Barreto Ketjen Corporation

T he integration of heavy and renewable feedstocks in fluid catalytic cracking (FCC) units has introduced unprecedented challenges related to metal contami - nation, particularly iron (Fe) poisoning, which severely com - promises catalyst performance through eutectic formation and accessibility loss. This article presents a comprehen - sive technical analysis of Ketjen’s proprietary SaFeGuard FCC catalyst technology, with a primary focus on the sec - ond commercial trial conducted at a major North American refinery (Customer Z) during June-July 2025. Improved accessibility vs Fe levels The trial achieved a 77% improvement in Ketjen Accessibility Index (KAI) with only 50% inventory changeout, increasing from KAI 3.5 to 6.2 despite elevated iron levels (0.48 wt% added Fe on equilibrium catalyst [E-cat]). Commercial per - formance demonstrated significant yield improvements, including +1.5 vol% liquefied petroleum gas (LPG) and -1.4 vol% bottoms, enabling increased vacuum tower bottoms (VTB) processing capacity. Laboratory testing of Upgrader and SaFeGuard E-cats from the FCC unit in an Advanced Cracking Evaluation (ACE) bench-scale FCC catalyst testing unit confirmed superior bottoms cracking (-0.57 wt%) and reduced coke formation (-0.63 wt%) at constant conversion. PetroSIM modelling validated commercial results, demonstrating a strong correlation between predicted and observed yield patterns. Scanning electron microscopy (SEM) analysis revealed significantly reduced nodule for - mation in SaFeGuard compared to conventional Upgrader technology. This validates the capability of a transformative catalyst technology to process challenging, metal-contam - inated feedstocks while maintaining or improving unit per - formance and profitability. Elevated metal contaminants The global refining industry is undergoing a profound transformation driven by sustainability mandates, circular economy initiatives, and economic pressures to process lower-cost feedstocks. FCC units, responsible for convert - ing heavy petroleum fractions into valuable light products, face escalating challenges as refiners integrate renewable feedstocks, waste plastics-derived oils, bio-oils, and oppor - tunity crudes into their processing schemes.

While these bespoke alternative feedstocks offer envi - ronmental benefits and improved margins, they introduce elevated levels of metal contaminants, particularly iron (Fe), calcium (Ca), sodium (Na), silicon (Si), and phosphorus (P), severely compromising conventional catalyst performance. Iron poisoning represents one of the most detrimental contamination mechanisms in FCC operations. At elevated temperatures in the regenerator (typically 650-750°C), iron interacts with calcium, sodium, silica and other elements to form low-melting eutectic phases. These glassy, molten eutectics spread across catalyst particle surfaces during regeneration, solidifying upon cooling to create dense, impermeable layers that occlude catalyst pores and dras - tically reduce catalyst accessibility. The operational con - sequences are severe: diminished catalytic activity, poor bottoms cracking capability, increased coke and dry gas yields, reduced apparent bulk density (ABD), leading to fluidisation problems, and ultimately reduced profitability. Laboratory studies using traditional cyclic deactivation protocols with metal contaminants significantly underes - timate the severity of in-unit accessibility loss, as these methods fail to replicate the eutectic formation and pore blockage observed in commercial operations. This gap between laboratory prediction and commercial reality has hindered catalyst development and left refiners without adequate solutions for processing metal-contaminated feeds. Conventional FCC catalyst technologies, including advanced accessibility formulations, provide limited resist - ance to iron poisoning. Ketjen Corporation addressed this challenge through a comprehensive research and development programme that included: u Development of a new metal deactivation (MD) labo - ratory protocol incorporating Fe and Ca to better simulate commercial deactivation mechanisms. v Establishment of KAI as a quantitative metric for diffu - sion-limited performance. w Formulation of SaFeGuard catalyst technology specifi - cally engineered to resist eutectic formation and maintain accessibility under high-metal conditions. The conventional lab-scale deactivation protocols do not reflect how iron affects catalyst accessibility. Ketjen’s new MD protocol better simulates the commercial catalyst

PTQ Q2 2026