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Editors Note:

FCC catalyst optimization has taken dif-ferent directions over the years but arecurring goal has been improving cokeselectivity. Ultimately, this would allowthe refiner to process heavier feed-stocks, increase unit throughput, andoperate within hardware limitations exac-erbated by the deleterious effects of

contaminants such as nickel and vanadi-um. Over half of refiners blend someresid into their feed.

Intense R&D efforts have resulted inmultiple generations of successful cata-lyst families with improved coke selectiv-ity. One such success story is theIMPACT series of catalysts. In this arti-cle, we discuss the application of IMPACTcatalyst in its early phase of com-

mercialization. It is clear that expectations of enhanced coke-to-bottomsbased on pilot plant studies were exceeded in the first commercial applica-tion some six years ago. IMPACTcontains the only integral vanadium trap inthe industry. In the years since, IMPACThas delivered enhanced coke andgas selectivity in a broad range of applications, from severely hydrotreatedgasoils to heavy resid feeds.

Since its initial commercial launch, we have sold over 200,000 tons ofIMPACTcatalyst and have employed the technology successfully in over 70

units worldwide.

Scott Purnell, principal author, serves as General Manager and Managing

Director of Advanced Refining Technologies. This article first appeared in

Issue #93, 2003.

www.e-catalysts.com22

A N N I V E R S A RY I S S U E


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In this article we will describe abreakthrough new resid catalysttechnology with unsurpassed cokeselectivity, known as IMPACT, andshare data from the first commer-cial applications of this promisingnew technology.

Breakthrough New Resid

Catalyst:IMPACT

Technology Description

Grace Davison is highly committedto its FCC catalyst business andhas an active R&D program todevelop and commercialize higherperforming products. Through ourstage-gate new product develop-ment process, we have successful-

ly commercialized the AURORA,ATLAS,AdVANTA, andVANGUARDcatalyst families within the last twoto three years. Recent efforts havefocused on further raising the per-formance bar for resid catalysts.Our scientists have strived to com-bine all the important catalyst func-tionalities for resid cracking intoone superior catalyst. The goal wasto invent a catalyst with step-outimprovements in coke selectivityand stability over current industry

benchmarks, VANGUARD andAURORA-LC, while optimizing the

matrix design for additional bottoms

cracking. Industry leading unit reten-tion characteristics and resistance toiron poisoning were also desired.

These efforts have led to the develop-ment of a breakthrough new residcatalyst family, known as IMPACT.IMPACT combines next-generationintegral vanadium trapping,advanced zeolite stabilization, andsuperior matrix metals passivation toachieve the ultimate in coke selectivi-ty, and has demonstrated truly

remarkable performance in laboratorytesting. Figure 1 illustrates one com-

Conversion, wt%

o

e,

w.

8

7.5

7

6.5

6

5.5

5

4.555 60 65 7570

DCR Testing on Resid FeedstockCPS Deactivation at 1450F:

2500 ppm Ni, 5000 ppm V

Coke Selective

Resid Catalyst Benchmark

Figure 1

IMPACTDelivers 30% Better Coke Selectivity

Figure 2

Stability of IMPACT

Total Metals (Ni+V) (ppm)

MATActivity

80

75

70

65

60

55

50

45

0 1000 2000 4000300040

5000 6000 7000 90008000 10000

CPS Deactivation at 1450F: Ni/V=0.5

Resid CatalystBenchmark

ConventionalCatalyst

parison between state-of-the-arttechnology and IMPACT. Thesedata were generated in the DavisonCirculating Riser (DCR) pilot plantwith a heavy resid feedstock. Thecatalysts were deactivated with2,500 ppm nickel and 5,000 ppmvanadium using our CPS cyclicdeactivation protocol. This figureindicates that theIMPACTtechnolo-gy offers nearly 30% improvementin coke selectivity. Improvements ofthis magnitude over industry-lead-ing technology are extraordinary.

In addition to coke selectivity, wehave also compared the stability ofIMPACT to industry benchmarks.Figure 2 summarizes a metalsdeactivation study that comparesIMPACT to a state-of-the-art cokeselective resid catalyst and a con-ventional FCC catalyst at increasinglevels of vanadium. This figureshows that both the resid bench-mark and IMPACT technologiesoffer a much higher tolerance to

vanadium than conventional cata-lysts (the curves are much flatter).Note however, that the activity curveof IMPACT is slightly flatter than theindustry standard, and the baseactivity achieved at 9,000 ppm totalmetals (Ni + V) is also higher.Comparing the zero metals case to9,000 ppm total metals, themicroactivity of IMPACT declinedonly about 2 numbers, while a



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Table II

Refiner A: Change in Operation with 30% Turnover toIMPACT

Table III

Refiner A: Commercial Yield Shifts with 30% Turnover to IMPACT

Table IV

Refiner B: Yield Shifts Observed in

Equilibrium Catalyst ACE Evaluation


particular case, the premium cokeselectivity of IMPACT is projectedto give an astonishing conversionincrease of 4.0 wt.%. Using typicalproduct values, this conversionincrease would translate into a$0.45/bbl advantage forIMPACT, or$22,500/day (greater than $8 mil-lion annually) for a 50,000 bpd resid

FCCU.

Commercial Experience

IMPACT is in the "CommercialTesting" stage of our new productdevelopment process and is cur-rently being evaluated in four com-mercial FCCUs. Data are still pre-liminary, but initial results are verypromising, meeting our high expec-tations for this exciting new technol-ogy. We will share some of the

highlights here.

In the first application, IMPACTwasadded to a UOP High Efficiencyunit in the US Gulf Coast. The unitruns more than 60,000 bpd of feedand operates in full combustion. Atonly 30% turnover to IMPACT, areduction in regenerator tempera-ture and an increase in catalyst cir-culation rate were observed (TableII). These observations are clearlyconsistent with the superior coke

selectivity of IMPACT.

The reduction in fresh catalyst addi-tions combined with increased con-taminants in the feed led to anincrease in equilibrium catalyst Ni +V levels of 30%. However, at only30% turnover and at the higher met-als level, IMPACTmaintained ecatmicroactivity and increased conver-sion by 1.3 vol.% while reducingdry gas. IMPACTalso dramaticallyreduced slurry. Yield shifts are

summarized in Table III.

In a second application in the USGulf Coast, IMPACT was added tothe inventory of another UOP HighEfficiency unit, operating in fullcombustion and charging morethan 50,000 bpd of feed. An ACEpilot plant study was conducted tocompare the performance of twoequilibrium catalysts taken from theunit one from prior to IMPACT

IMPACT@ 20% Turnover

(Change from Base Case)

Coke, wt.%

Delta, wt.%

Conversion, wt.%

Hydrogen, wt.%

Dry Gas, wt.%

LCO, wt.%

Bottoms, wt.%

Base

-0.05

+2.0

-0.06

-0.2

-0.4

-1.6

Change from Base Case

Regenerator Temperature

Catalyst CirculationCat-to-Oil Ratio

Fresh Catalyst Additions

-12F

+4.8 tons per min+0.5

-15%

Change from Base Case

Conversion

Dry Gas

Gasoline

Slurry

+1.3% vol.%

-12 scf per bbl feed

+1.1 vol.%

-2.3 vol.%


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Figure 7

Expansion at Davisons Lake Charles Plant to Produce IMPACT


through new resid catalyst knownas IMPACT. IMPACT has shownextraordinary enhancements in bothcoke selectivity and stability overcurrent industry benchmarks in pilotplant testing, while also providingstep-out improvements in coke-to-bottoms selectivity. SinceIMPACTisbased on Davisons proprietary alu-

mina sol technology, industry-leadingunit retention and resistance to ironpoisoning are additional benefits.

IMPACT is now available in commer-cial quantities and is currently beingevaluated in four FCCUs. Data arestill preliminary, but initial results arevery promising. Dramatic improve-

ments in coke and gas selectivitieshave been observed in the Ecatdata from the start of IMPACTaddi-tions and track with turnover. In twoof the applications, increases inconversion of 1-2 vol.% (mainlygasoline at the expense of slurry)have been observed with only 20-30% IMPACTin inventory.

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