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Value Driven Catalyst Developments in FCC Pretreatment Service
September 5, 2006Presentation By: Fernando Maldonado
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A New Family of FCC Pretreatment (PT) catalysts
DN-3551 NiMo
DC-2551 CoMo
to help refiners meet clean fuel requirements.
Improved Life Cycle Value
Value Driven Catalyst Developments in FCC Pretreatment Service
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The Reason for the Highest Score on Life Cycle Value
DN-3551 NiMo and DC-2551 CoMo for FCC Pretreat Applications
Flexible feedstockcapability/stability
• Wide pore catalyst technology improved
Multi cycle useeconomics
• Strength/activity recovery from conventionalregeneration
FCC conversionFCC properties• Top tier performance
• Flexible delivered state
• Reduced catalyst densityLoading/shipping/turnaround cost
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Start with a commercially proven optimized pore size distribution.
200 Series ExtrudatePrevious FCC PTCatalyst
Comparison of Pore Size Distribution
DN-3551 and DC-2551 exhibit similar pore size distribution
Increase of MPD and removal of small feeder pores allows the 200 extrudates to have increase metals pickup and deactivation tolerance
Pore Size Dist.
The Making of a Great FCC PT Catalyst
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Start with a commercially proven optimized pore size distribution of 200 series of catalysts.
DN-3551 and DC-2551 improve on metals uptake and hence stability
DN-3551NiMo
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DN-3551 NiMo and DC-2551 CoMo Improve DiffusionModified the pore shape geometry using
200 Series DN-3551DC-2551
Pore Shape Design ChangeReduced Bottlenecking
DN/DC200, DN3110/DC2118
FCC Pretreat Feedstocks have diffusion limitations
The Making of a Great FCC PT Catalyst
Metals Accumulation
DN-3551 NiMo and DC-2551 Improve Metals Uptake
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Improved Diffusion + = ……
90%
100%
110%
120%
130%
140%
Rel
ativ
e A
ctiv
ity p
er A
ctiv
e M
etal
HDS HDN
Metals Efficiency
Previous Technology ASCENT Technology
More Active Sites and Improved Metals Efficiency
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DN-3551 NiMo Catalyst for FCC PT services
100 100
105
125
115
135
90
100
110
120
130
140
150
Relative Volumetic
Activity
ConventionalNiMo
Type IINiMo
ASCENT DN-3551 NiMo
HDSHDN
DN-3551 Improves on CENTINEL Performance
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Major Global Refiner Criterion FCC PT Catalysts Ranking
91
100
104
109
85
100
113
139
80
90
100
110
120
130
140
150
RN450 DN200 DN3110 DN3551
RVA
HD
S an
d H
DN
-10
0
10
20
30
40
50
60
SCF/
BB
L D
elta
from
DN
200
HDSHDNH2 Cons Delta
Pilot ConditonsLHSV: 1.0H2 PP: 1200 psigH2/Oil:2000 scf/bblWABT: 650/690
DN-3551 Improves on CENTINEL Performance
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DN-3551 NiMo Increases Demet CapacityCommercial Unit FeedBack
5 ppm Metals in Feed
Metals U
ptake, wt%
Prev NiMo DN-200 DN-3551 CC DemetDN-3110
17%
23%24%
8%
Increased metal capacity translates into better stability
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FCC Pretreat (FCC PT) and FCC Technology Application
Dry Gas
C3/C4=
Gasoline
LightCycle Oil
HeavyCycle Oil
Slurry
FCC UnitFCC Feed Components:Naphtha,Diesel,VGO/HVGO
KGO/HKGO,Resid,DAO
FCC Pretreat Unit
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Maximize FCC Conversion with DN-3551 NiMoFCC Pretreat Unit
Conv. NiMo DN-3551NiMo Type II NiMo
S, wt% 0.15 0.14 0.13N, ppm 900 800 665 Di+ Aro, wt% 5.5 5.2 4.6
Produced FCC Feed
+0.6 +1.2
-12 -26
-0.4 -0.8
FCC Unit NiMo DN-3551Type II NiMo
GasolineYield, v%
*Yields Relative to Conventional NiMoConv. NiMo FCC gasoline sulfur = 112 ppm
GasolineSulfur, ppm
LCOYield, v%
FCC Conv, v%Econ Benefit$MM/yr
+0.8 +1.6
+4.5 +8.5
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Maximize FCC Gasoline Sulfur Reduction with DC-2551 CoMoFCC Pretreat Unit
Conv. CoMo DC-2551NiMo Type II CoMo
S, wt% 0.15 0.10 0.09N, ppm 900 900 900 Di+ Aro, wt% 5.5 5.5 5.3
Produced FCC Feed
CoMo DC-2551Type II CoMo
+0.0 +0.2
-37 -45
-0.0 -0.1
+0.0 +0.3
+0.0 +1.4
Minimize FCC Conversion Loss
FCC UnitGasolineYield, v%
*Yields Relative to Conventional NiMoConv. NiMo FCC gasoline sulfur = 112 ppm
GasolineSulfur, ppm
LCOYield, v%
FCC Conv, v%Econ Benefit$MM/yr
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New Additions to the Family of Catalysts
DN-3110 / DC211840% / 60%
NiMo / CoMo
DN3551 / DC2551 50% / 50%
NiMo / CoMo
ActivityImprovement
12 °FHDN
HDSHDN
SOR VGO Unit Commercial Performance – Example 1
6 °FHDS
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New Additions to the Family of Catalysts
Competitor30% / 70%
NiMo / CoMo
DN3551 / DC255150% / 50%
NiMo / CoMo
ActivityImprovement
10 °F HDS
HDSHDN
SOR VGO Unit Commercial Performance – Example 2
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Multi-Cycle Usage Economics
ASCENT Improves Regenerability of High Activity Catalysts
FRESH
Catalyst Age
Regenerated ASCENT Catalyst
Base
- 2oC (- 4oF)
+ 2oC (+ 4oF)
Base
- 2oC (- 4oF)
+ 2oC (+ 4oF)
HDS Activity Recovery ≥ 90%
Regenerated Type II Site Catalyst
+ 4o oF)oC (+ 7o
o+ 6 o
C (+ 14 F)+ 8
C (+ 10 F)
Historical Regenerated Catalyst
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Multi-Cycle Usage Economics
Maximize Regeneration Recovery
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Catalyst A DN-3551% Recovery from Regeneration 85% 95%Make-Up Catalyst Requirement, ft3 877 292
Cost of Regeneration, US $ $920,000 $120,000Make-Up Catalyst Cost, US $ $370,000 $110,000
MultiCycle Use Cost, US $ $1,290,000 $230,000
MultiCycle Use Cost Benefit, US $ $1,060,000
Multi-Cycle Use Cost Analysis
Multi-Cycle Usage Economics
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New Additions to the Family of Catalysts
DN-3551 NiMo3.5 MMlbs Sold5 Units
DC-2551 CoMo0.6 MMlbs Sold2 Units
• Top tier performing catalysts to deal with severe FCC PT services• Another step out in metals uptake and tolerance• Catalysts that provide ease of handling • Catalysts that easily regenerate by conventional techniques
