AM-93-53 RESID FCC CATALYST TECHNOLOGY: TODAY AND THE FUTURE

Description:

Fluid cracking catalyst can be designed with properties to resist the poisoning effects of contaminant metals like Ni and V. Catalyst supports can be designed so that they interact strongly with Ni and reduce its tendency to catalyze undesirable dehydrogenation reactions. This interaction can be verified by oxygen chemisorption analysis of laboratory steamed or equilibrium catalysts. Grace Davison catalysts based on this technology have gained wide commercial acceptance. Vanadium poisons cracking catalyst due to formation of vanadic acid in the commercial FCC regenerator, which attacks the zeolite. Basic compounds (e.g., alkaline earth oxides and lanthanides) can be used to trap vanadium and protect the zeolite. These traps can be incorporated into a cracking catalyst (integral catalyst approach) or formed into a separate particle (additive approach). This paper discusses the development of both technologies. New laboratory techniques that realistically assess catalyst metals tolerance are also described.