Maximizing Refinery Profitability with Next Generation Alumina-Sol FCC Catalyst Technologies: IMPACT~(TM), LIBRA~(TM), POLARIS~(TM) and PINNACLE~(TM)

摘要

An understanding of catalyst-feed interactions on a molecular level is key to developing value-added FCC catalyst technologies. Studies by Grace Davison researchers have shown that catalyst activity and selectivity may be significantly influenced by both the boiling point distribution and chemical composition of the feedstock. More recent studies involving detailed molecular analyses have revealed that the conversion of heavy feed molecules occurs via three reaction pathways each requiring a different catalytic function: i) precracking and feed vaporization that is facilitated by catalytic sites in the matrix; ii) dealkylation of alkylaromatics that is facilitated by the zeolitic function in the catalyst; and iii) conversion of naphthenoaromatics that is facilitated by catalytic sites on the matrix or the external surface of the zeolite. Knowledge of these reaction pathways has led to further advances in the design and performance of alumina-sol FCC catalysts. This has culminated in the successful commercialization of several new catalyst series that are based on new high activity, ultrastable zeolites in combination with novel Tunable Reactive Matrices (TRM~(TM)). Through the combination of unique pseudocrystalline aluminas, Grace Davison's alumina-sol binder system, and novel proprietary processing, matrix pore size distribution, acidity, and surface chemistry can be tailored to provide optimal coke- selective bottoms-cracking matched to feedstock characteristics and unit constraints. In this paper we introduce these new catalyst series, discuss their design and present commercial performance data.