PTQ Q2 2026 Issue

unit, the combined benefits of +1.5 vol% LPG ($20-30/bbl) and -1.4 vol% bottoms (negative value product) represent approximately $15-25 million per year in improved product value. Implications Key implications from the two independent commercial catalyst trials include: • Optimising heavy crude processing. The refining industry faces increasing pressure to inte- grate renewable and waste-derived feedstocks to meet carbon intensity reduction targets and circular economic objectives. Vegetable oils, forestry residues, bio-oils, agri- cultural byproducts, and waste plastic pyrolysis oils all contain elevated metal levels that challenge conventional catalysts. Demonstrated tolerance to Fe, Ca, and other contaminants removes a critical barrier to renewable feed co-processing, potentially enabling up to 10% renewable content in FCC feeds without performance penalties. Opportunity crude processing strategies rely on maxim- ising conversion of heavy, discounted feedstocks. These crudes inherently contain higher metals levels, and tradi- tional approaches required expensive feed pretreatment (hydrotreating) to reduce contaminant levels. However, cost-effective catalyst technology that can potentially reduce the severity of required pretreatment enables refin- ers to process cheaper, heavier crudes more economically. Iron poisoning typically causes progressive performance degradation that eventually necessitates catalyst dump- and-recharge or feedstock changes to restore performance. By maintaining accessibility under high-metal conditions, SaFeGuard may enable extended operation on contami- nated feeds before intervention is required, improving unit reliability and reducing turnaround frequency. • Reducing capital investment requirements. • Supporting decarbonisation objectives. • Enabling renewable and circular feedstocks. Conventional solutions to iron poisoning often involve expensive unit modifications: additional feed pretreatment capacity, enhanced regenerator systems, or dedicated met- als capture devices. These trials demonstrate the availa- bility of a catalyst-based solution that requires no capital investment, only catalyst changeover, making it accessible to refiners with constrained capital budgets. Comparison with alternate technologies Several alternate approaches exist for managing iron con- tamination in FCC operations, each with distinct advan- tages and limitations, including: • Feed pretreatment. • Metals passivation additives. • Increased catalyst addition rate. • Conventional high-accessibility catalysts. Feed pretreatment removes metals through adsorption onto hydrotreating catalysts prior to FCC feed. While effec- tive, this approach requires substantial capital investment ($50-200 million for new units), ongoing operating costs (hydrogen consumption, catalyst replacement), and energy consumption.

Iron poisoning in FCC units can be partially controlled by increasing fresh catalyst addition or through E-cat flush- ing. However, these approaches entail considerable costs and may require substantial time to effectively manage iron accumulation on catalysts, even following a single incident of Fe incursion. Conventional high-accessibility catalysts provide excellent performance under moderate metal levels but show inadequate resistance to iron poi- soning, as demonstrated in this study when compared with SaFeGuard’s enhanced metal tolerance. Competitive positioning based on the new high Fe-tolerant catalyst technology occupies a unique position as the only commercially proven FCC catalyst technology specifically designed and validated for high-iron envi- ronments, offering performance benefits without capital investment or operating complexity. Conclusions High Fe-tolerant catalyst technology SaFeGuard emerges as a pivotal advancement for refiners seeking dependa- ble performance under increasingly challenging feed and operating conditions. Its ability to preserve catalyst acces- sibility, despite significant metal contamination, supports more robust conversion behaviour, helping maintain prod- uct quality and operational stability even when processing heavier or iron- laden feeds. The consistent alignment between laboratory testing, commercial trials, and process modelling builds a uniquely strong foundation of evidence, demonstrating that the technology not only withstands severe metal interference but also sustains favourable product selectivity and cata- lyst health across diverse unit configurations. SaFeGuard also contributes to broader operational reliability by reduc- ing catalyst consumption rates and upholding key physi- cal properties, enabling refiners to push unit boundaries without requiring equipment modifications or major capital commitments. Its compatibility with the growing use of renewable or unconventional feedstocks further strengthens its rele- vance, allowing refiners to navigate the evolving energy landscape while retaining processing flexibility and eco- nomic competitiveness. Together, these attributes estab- lish SaFeGuard as a strategically significant solution that enhances refinery resilience while supporting long-term sustainability initiatives.

SaFeGuard and UPGRADER are marks of Ketjen.

The Petro SIM process simulation software platform is a mark of KBC (A Yokogawa company).

Scott Barton is FCC Technical Service Advisor at Ketjen Corporation in Houston, Texas, USA. Deependra Parmar is Research Engineer at Ketjen Corporation in Houston, Texas, USA. Eswar Iyyamperumal is Research Chemist at Ketjen Corporation in Houston, Texas, USA. Manuela Beatriz-Barreto is Marketing Manager for FCC technologies at Ketjen Corporation in Houston, Texas, USA.

PTQ Q2 2026