solutions, continuous process optimisation, and a close technical partnership. The successful trial of Denali AFX at Taiyo’s FCC unit demonstrated that advanced catalyst technology can enable refiners to process heavier, more contaminated feeds while maximising propylene yields and maintaining operational reliability. Notably, Denali AFX delivered an incremental profit of $0.25 per barrel at constant feed quality, with an additional $0.11 per barrel profit realised from throughput constraint relief due to lower regenerator temperature. Catalyst innovation for enhanced iron tolerance Catalyst innovation in the FCC industry has become essential for enhancing tolerance to metals contamination, especially iron, which poses significant operational and economic challenges for refiners. Iron poisoning occurs when mostly organic iron from feedstocks or process equipment deposits onto the external catalyst surface, leading to vitrification and the formation of glassy eutectic phases with other metals such as calcium, sodium, and silicon. This glassy layer occludes the catalyst’s pores, restricting the diffusion of larger hydrocarbon molecules and preventing them from reaching active cracking sites. “ Catalyst innovation in the FCC industry has become essential for enhancing tolerance to metals contamination, especially iron ” As a result, catalyst activity and bottoms cracking decline, selectivity is compromised, and the efficiency of bottoms cracking deteriorates, causing increased coke and slurry yields and ultimately reducing profitability. Iron poisoning can trigger the formation of nodules on catalyst particles, lowering their apparent bulk density (ABD) and causing fluidisation and circulation issues in the FCC unit standpipes. These operational problems can force unplanned unit shutdowns when standpipe defluidisation or loss of catalyst circulation occurs. To address these challenges, Ketjen’s has
developed SaFeGuard. This catalyst technology employs a unique matrix and Fe-resistant chemistry that retains excellent diffusion properties and catalyst accessibility even under extreme iron contamination. By minimising eutectic formation and keeping catalyst pores open, it enables refiners to operate FCC units at higher activity levels, process heavier and more contaminated feedstocks, and maintain effective bottoms cracking. This technology also demonstrates superior resistance to other contaminants, such as calcium, sodium, silicon, magnesium, nickel, and vanadium, making it highly effective for co-processing renewable feeds and unconventional crudes. Commercial trials have shown that SaFeGuard can deliver up to a 130% increase in catalyst accessibility, expressed by the Ketjen Accessibility Index (KAI). Consequently, it delivers improved unit activity and enhanced operational reliability, all while reducing catalyst addition rate. Such innovations are redefining what is possible to process in an FCC unit, empowering Case study: enhancing FCC catalyst performance under iron contamination A major North American refiner wanted to increase the amount of vacuum tower bottoms (VTB), a heavier, less refined part of crude oil, in their FCC unit feed. Processing more residue can help a refinery reduce feedstock costs and boost profitability, but it comes with a big challenge: the residue is contaminated with iron. Increasing residue in the feed risked reducing overall profitability and reliability. The refinery faced the possibility of lower product yields, higher costs for catalyst replacement, and more operational disruptions. Iron poisoning was not just a technical challenge – it was a barrier to achieving the refinery’s strategic goals. To solve these problems, they switched half of their FCC unit’s catalyst to SaFeGuard during a commercial trial. The unit processed a mix operators to maximise profitability and operational flexibility in an increasingly demanding feedstock landscape. of heavy feeds, with a focus on maximising the amount of residue. After the switch, clear improvements were observed:
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