Catalysis 2023 Issue

Finding the best catalyst

catalysis ptq

2023

P ursuit of high-margin products, including olefins and aromatics, requires higher refinery complexity and integration with petrochemical infrastructures. This year’s annual publication of PTQ Catalysis 2023 reflects these evolving trends, as well as unexpected developments such as diesel profitability and the cata - lytic systems used in their processing. New catalyst formulations discussed in this issue are further synchronised with reactor improvements. In certain cases, catalysts have been developed as a stand-alone solution to avoid capital investment for higher reactor capacity, larger compressors, and pre- treatment requirements, such as with the current opportunity to increase diesel demand. Transportation fuels output is projected to level off, but not so fast. High margins currently seen with fossil fuel-based middle distillates (i.e., diesel) seem to contradict this projection. Going forward, ‘co-processing’ of second- and third-generation biofuels in tra- ditional refinery units such as the FCC and hydrocracker could keep the trans - portation fuels margins competitive vs electric-powered vehicles. For example, the US-based Energy Information Administration (EIA) projects that renewable diesel capacity in the US could more than double through 2025. However, the EIA noted that India and China hold the promise of more than doubling global biofuel demand growth in the long term. Proven catalyst formulations, such as for ULSD production, have been serv- ing refiners worldwide for nearly 20 years. However, recent enhancements, such as new pore structures, allow the processing of heavier refractory feedstocks containing a wider range of contaminants. Increasing cycle length and reducing annualised shutdown costs compels continuous investment to deal with new con- taminants challenges, such as co-processing fossil fuel-based hydrocarbons with biofeedstocks. It is no secret that finding the right combination of catalyst and reactor internals is essential for enhancing catalyst activity, selectivity, and stability and mitigating catalyst changeout frequency while ensuring reliable operation. In addition, CFD reactor and flow modelling allow process technology and catalyst developers to obtain a better understanding of feed quality and tailoring of catalyst systems. Whatever catalytic conversion process is under consideration (FCC, hydrocrack- ing, hydrotreating), the common thread involves fouling and contaminants removal, such as metals, sulphur, and nitrogen. Another common thread in the downstream catalysis lexicon involves a catalyst vendor’s ability to offer a tailored combination of catalysts to meet conversion and selectivity while taking into account equipment design, hydrogen availability, and cycle length. New parlances unfamiliar to refiners a generation ago are now mainstream, such as co-processing of second- and third- generation renewable feedstocks. The FCC unit is one of the best conversion units for co-processing unconventional feedstocks, but more intense co-processing through the FCC unit could significantly impact catalyst deactivation. To manage these types of challenges, we are seeing catalyst suppliers provide a wider range of technical support capabilities, including FCC unit monitoring and modelling of new feedstocks under consideration. Above all, with competitive refinery and petrochemical suppliers having to find creative ways to optimise profitability while reducing a facility’s carbon footprint, it is imperative to apply best practices toward molecular and energy management in the development of best-in-class catalysts and processes.

Editor Rene Gonzalez editor@petroleumtechnology.com tel: +1 713 449 5817 Managing Editor Rachel Storry rachel.storry@emap.com Graphics Peter Harper US Operations Mark Peters mark.peters@emap.com tel: +1 832 656 5341 Business Development Director Paul Mason sales@petroleumtechnology.com tel: +44 7841 699431 Managing Director Richard Watts richard.watts@emap.com Circulation Fran Havard circulation@petroleumtechnology. com

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PTQ (Petroleum Technology Quarterly) (ISSN No: 1632-363X, USPS No: 014-781) is published quarterly plus annual Catalysis edition by EMAP and is distributed in the US by SP/Asendia, 17B South Middlesex Avenue, Monroe NJ 08831. Periodicals postage paid at New Brunswick, NJ. Postmaster: send address changes to PTQ (Petroleum Technology Quarterly), 17B South Middlesex Avenue, Monroe NJ 08831. Back numbers available from the Publisherat $30 per copy inc postage.

Rene Gonzalez

Catalysis 2023