Catalysis 2024 Issue

Incumbent Fourte Valor

2700

2900

3100

3300

3500

3700

2700

2900

3100

3300

3500

3700

V + Na (ppm)

Conversion (vol%)

Figure 5 FCC trial results of Fourte Valor catalyst vs incumbent catalyst

in FCC, the true test of a technology is its performance in an industrial FCC unit. The following discussion reviews three trials with different FCC objectives in which novel vana- dium passivation technologies were used to improve FCC performance. The first trial occurred in a North American FCC unit, which processed a feed containing elevated levels of vanadium and sodium. The objective of this FCC case is to reduce slurry and maximise butylenes. To achieve this goal, it was believed that BASF’s proprietary Fourte FCC catalyst could better achieve these results compared to the existing catalyst. Given the high amount of vanadium present, it was agreed that advanced vanadium passivation technology would also be needed. Thus, Valor technology was used in the catalytic system. Figure 5 shows the results from the trial of the new catalyst. The results clearly indicate multiple improvements to the catalyst system. First, the benefit of improved vanadium pas - sivation can be seen as the amount of zeolite retained by the catalyst compared to fresh catalyst. Zeolite surface area (ZSA) increased by 4-5% at comparable contaminant levels. The impact of this is clearly seen in the Ecat activity of the FCC system following the introduction of Valor, as activity increases 1-2 wt% at a similar contaminant amount. Fourte catalyst is a technology that uses multiple zeo- lite frameworks to maximise butylene yields. By using this catalyst in combination with a strong technology to guard against vanadium passivation, the improvements in FCC per- formance can clearly be seen. The new catalyst technology increased butylene yields by 1-2 vol% and reduced slurry yield by 0.5 vol%, thus helping the FCC unit achieve two major objectives. This trial result was also key, as it demon- strated that the strong vanadium passivation technology can work in parallel with an FCC catalyst designed for the maxi- misation of light olefins, including butylene.

The second trial is from an Asian FCC that processed resid feed and had a goal to maximise production of pro- pylene while minimising slurry yields. BASF Maximum Propylene Solution (MPS)-Valor was selected as the FCC catalyst to achieve these targets. MPS is designed for max - imum propylene yield and selectivity through the optimum use of zeolite-Y, rare earth level, and olefins additive. The Valor technology was necessary given the high levels of vanadium and sodium present in the FCC feed. Table 1 shows the results from the second trial. Overall, the FCC achieved a 2.6% higher propylene yield, a 0.6% increase in conversion, and a 4.8% decrease in slurry yield compared to the prior catalyst. This was done using lower catalyst additions (8.1% lower), lower riser outlet temperature (20°F lower), and less olefins additive (12% lower Ecat Phosphorous [P]). This is significant as riser outlet temperature (ROT) and olefins additive are two key levers for increasing propylene yield and demonstrate the

Key results from Trial 2

Incumbent MPS-Valor Change

Feed rate

-3.9% -2.1% 77.4% -8.1% 29.5% -12.0%

ROT, °F

1,000.0

978.6

Slurry recycle, vol%/vol% Catalyst addition, lb/bbl

1.77

3.14

Ecat vanadium + sodium, ppm 3,926

5,085

Ecat P, wt%

1.02

0.90

Dry gas yields, wt%

3.7

3.4

-8.7% 2.6% 0.6% -4.8% 0.6%

C 3=, vol%

13.8 0.35

14.1 0.35

C 3=/LPG, vol%/vol%

Slurry, vol%

5.2

4.9

Conversion, vol%

83.5

84.0

Some data omitted at request of refiner.

Table 1

Catalysis 2024