AM-11-01Multi-Stage Reaction Catalysts: A Breakthrough Innovation in FCC Technology

Description:

The manufacturing process for this unique approach is based on BASF’s in situ technology and involves several key sequential manufacturing steps. One of the important attributes in the development of MSRC technology is the binding process. Unique to the in situ FCC manufacturing process, Y zeolite grows across the boundary between catalyst stages, acting as a binder and giving the catalyst particle excellent attrition resistance properties. The first product, Fortress™, from this new platform is designed for resid feed applications, where contaminant metals passivation is critical. In particular, traces of nickel in the resid feed have a detrimental effect on the catalyst performance due to dehydrogenation reactions leading to coke and hydrogen production. In state of the art resid catalysts, a nickel trap based on specialty alumina is used to trap the nickel and render it less detrimental (Ref. 2). By using the MSRC concept, the spatial distribution of this specialty alumina within the particle is adjusted to maximize its efficiency in nickel trapping and lead to improved catalyst performance. The MSRC manufacturing technology was successfully scaled up and demonstrated in 2010 and two refinery trials were initiated. This paper discusses the results of this effort.