Industry-leading FCC Pretreatment Catalyst Solutions

Refiners worldwide are reporting significantly enhanced refinery economics after working with Shell Catalysts & Technologies to optimise the performance of their integrated Fluid Catalytic Cracking (FCC) complexes.

Shell Catalysts & Technologies offers a range of industry-leading FCC pretreatment catalyst solutions and works closely with refiners to design catalyst systems that match their specific performance goals. We follow a highly diagnostic process in which we listen to customers to gain a thorough understanding of their situation. This enables us to devise a value-adding catalyst system designed to lie within those constraints and leverage the most value from their assets.

Success in this application with a large variety in feeds and objectives requires catalyst systems that combine main-bed catalyst performance with SENTRY portfolio protection from poisons and foulants ; integrated offerings for improved process performance upstream, internal, and downstream from the CFH; and technical excellence to develop, monitor and optimise unit performance.

Sustaining leadership in this application comes through the cornerstones of ensuring day-to-day performance together with continuous improvement, technical expertise, and focused research & development program that has been providing market-leading FCCPT solutions for years. These cornerstones are enabled by broad-based refining knowledge, an ability to engage, diagnose, develop and lead change and an ability to gain customers trust and grow long-term relationships.

Building on the proven capability and reliability of the CENTERA™ technology platform, Criterion is now delivering the CENTERA GT™ level of performance. In the FCC Pretreat application, performance is measured by many metrics and success is achieved through the application of a custom-designed catalyst system. Enabling continued FCCPT performance gains, three new products have been developed providing top-tier performance in HDS, HDN, and AroSat while maintaining the proven stability and contaminant tolerance Criterion FCCPT catalysts have been well known for.

Catalyst Type/Applications Description
DN-3655 FCC Pretreat

CENTERA GT DN-3655, a step-out Type II nickel-molybdenum catalyst for FCC feed pretreatment (FCC-PT). Compared to previous generations, CEN-TERA GT DN-3655 provides significant nitrogen removal (HDN) and sulfur removal (HDS) improvements. It is especially well-suited for high-quality FCC feed production in moderate to high-pressure units processing difficult feeds, where nitrogen removal and hydrogenation reactions are valued to improve FCC conversion levels.

CENTERA GT DN-3655 enhances HDS and HDN performance and stability across a broad range of scenarios, particularly in high severity applications that require maximum activity to overcome unit limitations. Applications where DN-3655 is particularly well-suited include:

  • Units where high hydrogenation activity can be utilised to increase nitrogen removal and aromatics saturation to produce high-quality FCC feed and enable increased conversion levels
  • Operations that process or want to process feeds having high nitrogen content, high percentages of cracked feed, or high endpoint
  • Debottlenecking existing operations, particularly if trying to process higher rates, process more difficult crude oils  or decrease overall feed quality.
  • Applications where it is advantageous to combine CoMo with NiMo catalyst to improve HDS performance to meet Tier 3 sulfur regulations while maintaining or increasing HDN and HDA performance levels
DN-3651 FCC Pretreat CENTERA® DN-3651 is Shell Catalysts & Technologies’ is an industry-proven high activity NiMo catalyst for moderate-to-high pressure FCC Pretreat operation. DN-3651 has very high HDS and HDN activity while it maintains ASCENT stability and metals capacity for improved cycle performance with exceptional polyaromatic saturation optimising FCC conversion
DN-3551 FCC Pretreat ASCENT DN-3551 is a widely used proven catalyst featuring high activity, exceptional metals capacity and stability for improved cycle performance and reliability when processing difficult feedstocks.

CENTERA GT DC-2655 is a new Type II Co-Mo with Ni promoter catalysts for FCC-PT service providing step-out gains in performance from previous generations. Enhances FCC Pretreat performance and stability across a broad range of scenarios, particularly in applications that require very high activity to overcome unit limitations. Applications where DC-2655 is particularly well suited:

  • In low-moderate pressure units where a poor-quality hydrogenation environment leads to high SOR operating temperatures and subsequently short cycle lengths
  • In units that operate at low-to-moderate pressures, especially when hydrogen supply is limited, and hydrogen optimisation is critical
  • Where it is desirable to debottleneck existing operations, extend run length, expand feed capacity, upgrade more difficult feed-stocks, or decrease overall feed quality
  • In moderate pressure applications where, when it is advantageous to combine a CoMo with a NiMo catalyst to enhance the overall HDS performance while controlling hydrogen consumption, DC-2650 is ideal for balancing consumption while providing activity benefit.

CENTERA™ GT DC-2656 is a new Type II Co-Mo with Ni promoter catalysts for FCC-PT service providing step-out gains in performance from previous generations. Provides the deep desulfurisation required to meet clean fuel requirements and flexibility to process heavier feeds, maximise ULSD cut points, and extend unit cycle length. DC-2656 is especially suited for high-quality FCC feed production in moderate-to-high pressure units where desulfurisation (HDS), denitrification (HDN), and hydrogenation reactions improve FCC conversion and reduce sulfur related operational constraints. Either by itself or combined with a customised catalyst system, DC-2656 generates balanced performance and superior FCC feed quality across a broad range of high severity scenarios requiring maximum activity. Applications where DC-2656 is particularly well-suited include:

  • Producing high-quality FCC feed for lower sulfur products, increased FCC conversion, and reduced regenerator SO2 emissions;
  • Processing feeds having high nitrogen, high percentage of cracked feed, or high endpoint;
  • Debottlenecking existing operations to enable higher feed rates, processing of more difficult crudes, or overcoming the challenges created by an overall decrease in feed quality;
  • Leveraging the advantages of combining CoMo with NiMo catalyst at moderate pressure to increase HDS performance while enhancing the overall FCC performance.
A Shell employee walking toward a reactor with FCC Catalysts.

Get More Out of Your Catalysts

We devise a value-adding catalyst system designed through a highly diagnostic process. We listen to customers to gain a thorough understanding of their situation and offer our experience to help our customers reach the best outcomes.

We recognise that simply installing industry-leading catalysts doesn’t guarantee best-in-class outcomes. Strategic design of the overall catalyst system is also critical. It is essential that this takes into account site-specific constraints such as hydrogen availability, FCC unit capabilities, and feedstock options.

Additionally, the refiner’s unique operational objectives must be factored into the catalyst system from the start. For instance, different refiners will have different targets for cycle life, product slate, and emission rates based on historical performances and goal-setting. With Shell Catalysts & Technologies, these goal-setting conversations drive our solution design process from the outset.

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Shell Catalysts & Technologies’ has a wide range of solutions to lessen effects for refiners of crude prices being unstable.

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