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Topic
The Building Blocks of Robust Hydroprocessing Unit Operations
Presented by :
Saurabh Dhir
Shell India Markets Private Limited
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Introduction
• An unplanned turnaround to replace catalyst early has severe financial consequences.
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Primary source is anti-foam agents used in delayed cokers
Also found in some crudes and flow improvers used in drilling
Relatively mild poison
Silicon
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Silicon removal involves reaction with hydroxyl groups present
on alumina support
For lighter feeds (naphtha and distillate), greater surface area
means increased Si capacity
Silicon
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Heavier streams contain large molecules which cannot fully
penetrate the catalyst pellet
Use of large pore diameter catalysts in VGO service helps to
maximize surface area utilization
Silicon
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Catalyst design for NHTs requires a balance between Si pick-
up and treating activity
Use of a inert, high surface area Si trap resulted in lower
exotherm and shorter cycle
Critical to balance Si pick-up & activity
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Usually found in DAO and high end point VGO & HKGO; feeds
contain 2 to 15 ppm Ni & V
Removal involves kinetic reaction followed by deposition on the
catalyst surface
Ni & V traps are designed with an optimum pore size distribution
and balanced activity
Nickel & Vanadium
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• A system designed for 7 ppm Ni & V observed rapid
increase in WABT after 1.5 years due to presence of Silicon
• A rebalanced load with increased demet provided stable
activity through 900 days on stream
Rebalanced load leads to longer cycle
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• A FCCPT unit observed an increase in feed metals due to
change in crude source and quality
• Catalyst system was optimized from 2% demet to 15% demet
resulting in a 30% increase in cycle life
30% longer cycle with optimum load
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• Found in many types of crude
• Severe poison
• Low level detection necessary (50 wppb)
Arsenic
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• Reacts with active metal to form Nickel Arsenide
• Arsenic trap exhibits better retention of activity while picking
up high concentration of Arsenic
• MaxTrap[As] has 50% greater pick-up
Arsenic
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• Higher pick-up capacity of the new MaxTrap[As] increased
the stability of the system resulting in a 30% increase in
cycle length
Longer cycle with MaxTrap[As]
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• Specialized catalyst for high CCR feeds (DAO, deep cut
VGOs) with superior HDCCR and demet activity
• Ni & V removal in an FCCPT unit is higher with MaxTrap[CCR]
• Stable CCR conversion with MaxTrap[CCR]
MaxTrap[CCR]
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➢ Balance demet and main catalyst volume while accounting for
unit limitations such as heat integration or maximum bed
delta T
➢ Take advantage of improved demet pick-up to extend cycles,
run higher margin crudes and heavier feeds
➢ More active and stable main catalysts allow operating
severity to be increased without sacrificing cycle life
➢ Use Catalyst Technology to maximize Profitability
Final Thoughts