Question
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How is contamination of FCC catalysts being resolved to increase yields and cycle length?
Mar-2025
Answers
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Mark Schmalfeld, BASF Refinery Catalysts, mark.schmalfeld@basf.com
FCC catalysts, specifically BASF FCC catalysts, are specifically designed to enhance the operation of fluid catalytic cracking (FCC) units. Catalyst design considers the context of contamination management expected for the feed types used by the FCC unit. Here are several ways in which FCC catalysts contribute to improved FCC performance, even in the presence of catalyst feed contamination.
FCC catalysts have been developed with enhanced metal tolerance, allowing them to maintain activity and selectivity even when exposed to feedstocks containing metals such as nickel and vanadium. This capability helps mitigate the negative effects of these contaminants, leading to more stable operation and improved yields, in addition to catalysts with near-zero levels of chlorides. Low sodium levels in FCC catalyst improve the zeolite stability. Use of an in situ manufacturing process designs the pore volume distribution to ensure a high level of iron tolerance.
FCC catalysts often incorporate advanced zeolite structures engineered to resist the deposition of contaminants. These optimised structures provide greater surface area and improved diffusion pathways, allowing for better hydrocarbon access and reduced accumulation of coke and other contaminants.
FCC catalysts are designed to facilitate effective regeneration as coke and hydrocarbon deposits are combusted in the FCC regenerator. Their design allows for the efficient removal of carbon deposits and some contaminants during the regeneration process, helping to restore and maintain the catalyst activity. This means that even in the presence of contamination, the catalysts can be regenerated more effectively when tailored to the specific unit constraints and targeted operating conditions.
FCC catalysts may include proprietary additives and design elements that specifically target and mitigate the effects of contaminants. For example, these additives can help neutralise harmful compounds or enhance the catalyst’s ability to cope with specific impurities, thus maintaining performance levels. Enhanced catalysts and activity can help offset the impact of contamination by ensuring that the FCC unit operates efficiently, even when feed quality fluctuates. An optimised activity level is required based on unit constraints and economics.
BASF’s FCC technical team can adjust catalyst design to provide refiners with operational flexibility to manage unexpected changes in feed quality. Additionally, catalyst design can be utilised to adjust how contaminated metals are removed from the FCC unit over time. This adaptability is crucial in maintaining stable performance and ensuring that the FCC unit can respond effectively to variations in contamination levels.
Equilibrium catalyst (Ecat) analysis is conducted and combined with operating data for refiners to enable continuous improvements in operational adjustments, troubleshooting, and opportunity development. This collaboration and partnership approach allows for ongoing optimisation of catalyst usage and operational practices, further enhancing overall performance.
Mar-2025
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