PTQ Q2 2025 Issue

Enhancing refinery profitability through rigorous catalyst evaluation

The role of independent catalyst testing offers unbiased assessments crucial for unit performance and quality

Tiago Vilela and Nattapong Pongboot Avantium

I n the complex world of petroleum refining, catalysts are integral to refining processes, enabling the conversion of crude oil into high-value products while significantly impacting operational efficiency and financial perfor- mance. Given the substantial costs associated with cata- lyst acquisition, typically ranging from $10 to $20 million, robust evaluation methodologies are essential for making informed decisions that align with production goals and market demands.1 Independent testing plays a pivotal role in this evaluation landscape, offering unbiased assessments that are crucial for identifying catalyst performance issues and ensur- ing quality. By engaging external experts, refineries can uncover defects that internal teams may overlook, thereby optimising catalyst performance. Despite their importance, many refiners fall into common pitfalls when selecting cat- alysts, leading to suboptimal performance and reduced profitability.² In summary, rigorous catalyst evaluation is paramount for enhancing refinery profitability. By implementing best practices in catalyst management, refiners can not only improve operational efficiency and reduce costs but also ensure compliance with evolving environmental standards and market expectations. The ongoing advancements in catalyst technologies further emphasise the need for inde- pendent testing.3 Rigorous catalyst evaluation The choice of catalyst affects both daily operations and long-term planning. As catalysts play a vital role in refin- ing processes, their selection directly influences the refin- ery’s production goals and overall financial performance. A well-executed catalyst evaluation ensures refineries operate with the most effective catalyst, maximising refin- ing margins and profitability while minimising operational risks. When selecting catalysts, refiners consider multiple fac- tors, including expected performance, cost, guarantees, technical support, and their past experiences with poten- tial suppliers. Key performance parameters are rigorously analysed, such as activity, yield selectivity, cycle life, deac- tivation rates, hydrogen consumption or production, and product properties.

To enhance evaluation accuracy, the process usually involves comparative catalyst testing in pilot plants under conditions that closely resemble commercial operations. This practice allows refiners to assess the economic impli- cations and performance capabilities of different catalysts, ultimately selecting the one that best meets their opera- tional needs.1 Rigorous catalyst evaluation not only optimises perfor- mance but also significantly impacts the economics of refin- ery operations. By improving yield and efficiency, effective catalyst selection can lead to substantial cost savings and increased profitability. Mistakes due to lack of testing are not uncommon, and some are very expensive. For example, in one US hydro- cracker, switching from the usual feed to deasphalted oil increased the catalyst deactivation rate by six-fold. In another example, a new catalyst increased middle distillate yields in a diesel-oriented hydrocracker by 5.6 wt%. The difference was so dramatic that it debottlenecked the entire refinery.1 Advantages Independent catalyst testing is the best practice for rigor- ous catalyst selection. It provides an unbiased evaluation of performance, ensuring that refiners select the most effec- tive catalysts for their units. The benefits include: • Providing actual performance data, uncovering catalyst performance shortcomings. Side-by-side comparison fos- ters a more accurate benchmarking of the catalysts, pro- viding reliable data on activity, hydrogen consumption, and the ability to process that feedstock, ultimately leading to improved performance. • Refiners can make better-informed decisions by com- paring multiple catalyst options based on objective perfor- mance metrics. A recent example for a diesel hydrotreating (DHT) unit catalyst selection showed that without testing, none of the catalysts proposed by suppliers would meet the target cycle length. • Selecting the best-performing catalysts leads to improved product yields, lower utility consumption, and the ability to process lower-cost feedstocks, ultimately enhancing refin- ery profitability. Small changes in naphtha reforming C5 + yield can significantly impact refinery margins. For example,

PTQ Q2 2025