Millennium

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There is a growing worldwide trend toward the use of lower cost resid feedstocks in fluid catalytic crackers. However, there is an important constraint: Resid feeds, in addition to being heavier and more aromatic than lighter feeds, also have higher metals content. The presence of nickel and vanadium organometallics results in more coke and gas... and limited throughput.

To make effective use of resids, refiners need improved FCC catalysts with better metals tolerance and the ability to retain activity in the face of severe operating conditions.

To meet their needs, Engelhard has developed Millennium, the first in a new generation of customized catalysts that passivate metals while simultaneously improving bottoms upgrading. These catalysts can provide refiners with more choices in setting FCCU operating conditions and therefore help them maximize throughput.

Engelhard specifically developed Millennium to outperform the best competitive resid catalysts (labeled A, B and C). Using these as a benchmark (Figure 6), Engelhard designed a catalyst that combines two proprietary technologies: a unique Quadra Functional matrix and PyroChem ultrastable zeolites.

Millennium utilizes a unique matrix design, called Quadra Functional because it:

1. Passivates nickel
2. Traps and passivates vanadium
3. Facilitates large molecule access to the matrix
4. Selectively precracks resid feeds

Our proprietary technology allows diffusion of nickel organometallics to sites where the organic portion is removed, leaving the nickel chemically bound to the matrix. Because of the surface chemistry and controlled porosity, the nickel is not available to promote unwanted dehydration reactions. Figure 1 shows Millennium produces 10-20% less coke and hydrogen in the presence of nickel than competitive resid catalysts.

Compounds containing vanadium likewise diffuse, and because of proprietary chemical treatment, react with the surface to prevent further migration of the vanadium to the zeolite. The nickel and vanadium tolerance of Millennium catalysts can be tailored to meet specific customer needs.

Stable zeolites with few crystal defects are especially important in the processing of resid feeds. To reduce the formation of crystal defects and provide zeolite stability in the regenerator, Millennium uses Engelhard's PyroChem zeolite ultrastabilization technology. The result: decreased catalytic coke and gas formation, plus increased gasoline selectivity. Figure 2 demonstrates that Millennium retains higher surface area and activity than three leading resid FCC catalysts.

With resids, 60% of all oil molecules in the feed are too large to fit into the 8-angstrom zeolite openings. Therefore, some precracking outside the zeolite must occur prior to selective zeolite cracking to lighter products. Thus, the rates of diffusion to an active matrix site become important. Millennium matrix structure facilitates diffusion to active matrix sites. As a result, Millennium provides superior bottoms upgrading, as measured by the increase in light cycle oil at constant converison (Figure 3), while minimizing coke and gas, as described above.

Millennium was designed to exceed the performance of today's benchmark resid processing catalysts. Extensive comparative testing was done under a variety of conditions, with gas oil and resid feeds, and using cracked-on and Mitchell method metal deposition technologies. These tests were conducted in fixed fluidized bed, as well as Mat units.

Figures 4 and 5 show results obtained in various tests comparing metallated and fresh Millennium catalysts with the competitive resid catalysts. These tests typically show reductions of 10% to 20% in coke and 20% to 40% in hydrogen...with better gasoline production.

There are wide differences in resid feedstocks, unit operating conditions and performance requirements. Millennium catalysts can be customized to provide refiners with the performance characteristics required to meet their specific needs.

Your Engelhard representative and the resources of Engelhard's Technical Service and R&D laboratories are available to help in the specification of catalysts customized to precisely fit your resid feedstocks, FCCU constraints and operating requirements.

Millennium catalysts are the newest members of the Engelhard family of petroleum catalysts and services. We provide many other high-performance products for use in hydrocarbon processing. These include FCC catalysts, moving bed catalysts, synthetic- and mineral-based sorbents. And through Acreon (an Engelhard/Procatalyse joint venture in North America), process technology and catalysts for reforming, isomerization, hydrotreating and selective hydrogenation are available.

In addition, Engelhard catalysts are the mainstay of a wide range of industries, including chemical, petrochemical, petroleum refining, food, power generation, automotive and mining including:

Chemical Catalysts: A range of catalysts and sorbents for the chemical, petroleum, petrochemical, pharmaceutical, edible oils and detergent industries, including catalysts used by the petroleum industry for lube oil and wax percolation and purification, olefin and aromatic hydrogenation and BTX purification.

Environmental Catalysts: For the control of emissions from on- and off-road vehicles, power generators and industrial motors, as well as to control emissions of nitrogen oxides, carbon monoxide and unburned hydrocarbons from refinery boilers, heaters and gas turbines.

Engelhard maintains sales and technical service facilities worldwide. For information, contact the Engelhard Sales Office nearest you.

Engelhard seeks to present reliable information concerning the composition, properties, and use of its products, however: (1) All advice concerning selection and use of any product is provided AT NO CHARGE AND WITH NO WARRANTY. (2) No warranty is made hereby. Products described herein are warranted to conform to Engelhard's specifications only at the time of sale. All sales are subject to Engelhard's standard terms and conditions, which are reproduced on the reverse side of each invoice. ALL WARRANTIES OF MERCHANTABILITY AND FITNESS OF PURPOSE ARE DISCLAIMED and remedy for any breach of warranty is limited to replacement of the defective product. (3) Engelhard assumes no responsibility for any patent liability arising from the use of any product in a process, manner or formula not designated by Engelhard. Nothing in the listed information shall be construed as an inducement or recommendation to use any process, or produce or use any product, in conflict with existing or future patents.