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A COMPREHENSIVE APPROACH TO CATALYST DESIGN FOR RESID APPLICATIONS

Scott K. Purnell, Davison Catalysts

Format:
Electronic (digital download/no shipping)

Associate Member, International Member, Petrochemical Member, Refining Member - $0.00
Government, NonMember - $25.00

Description:

As the availability of light, sweet crudes has declined and prices have increased, refiners have reconfigured their operations in order to be able to upgrade heavier, less desirable feedstocks into lighter, more valuable products. Declining fuel oil demand has only added to the urgency for effective upgrading of heavy resid. Fluid Catalytic Cracking is one of the most efficient and economic ways of achieving this upgrading, and it is estimated that about half of the refiners blend some amount of resid into their FCC feeds. For resid operations, the proper design of the FCC catalyst is a critical part of the overall process optimization. Obviously, minimizing diffusional limitations for the large molecules found in resid is an important consideration in the design of resid catalysts, but it is not the only one. For resid-feed units whose performance is impacted by contaminant metals and high feed carbon, catalyst coke selectivity is the most important catalyst performance characteristic. Catalyst stability and metals tolerance are paramount. Feedstock properties along with the dominant bottoms cracking mechanisms characteristic of the feed must also be considered when designing zeolite and matrix activity. Resistance to less common catalyst poisons such as iron is critical for many refiners, and catalyst physical properties and their impact on unit retention cannot be ignored. In this paper, we will examine the importance of each of these attributes in the optimal design of resid catalysts with examples of the effects on catalyst performance. Finally, we will introduce a breakthrough, new catalyst technology for resid cracking known as IMPACT™, whose design resulted from the optimal integration of all these functionalities. Preliminary results for IMPACT have shown truly step-out yields and selectivities, which promise to dramatically raise the performance bar for challenging resid applications.

Product Details:

Product ID: AM-03-126
Publication Year: 2003