Hydrocarbon Processing - December 2022 - 35
Special Focus Catalysts
N. PONGBOOT, Avantium, Amsterdam, the Netherlands; and
T. UPIENPONG, PTT Global Chemical, Rayong, Thailand
Refinery catalyst selection: Facts and fictions
every refiner should know
Most refiners carefully evaluate their
refining catalysts to ensure maximum benefits
over the catalyst cycle length. Without
a doubt, pilot plant testing is the best method
to evaluate true catalyst performance.
Often, the incremental catalyst cost is trivial
compared with the economic benefits
from improved catalyst performance.
To the authors' surprise, many refiners
only consider testing some refining
catalysts, such hydrocracking, fluid catalytic
cracking (FCC) or naphtha reforming
units. This seems a reasonable line of
thought, as these refining units are the
critical profit makers of a typical refinery.
So, why risk not testing?
Conversely, these refiners somehow
believe testing other refining catalysts
(e.g., diesel hydrotreating catalysts) is unnecessary.
They argue that other refining
catalysts are less critical and a paper-based
evaluation is usually sufficient. This notion
seems sensible on the surface, and
many refiners follow this practice. However,
is this really the case? Should refiners
consider an 86,000-bpd diesel hydrotreater
(like the one shown in FIG. 1)
as not critical? Where is the line defining
the criticality? Is a paper-based evaluation
even a valid method? This article will answer
these questions and emphasize why
refiners should remain skeptical about
skipping refinery catalyst testing.
Reliance on a paper-based catalyst
evaluation. Many refiners think that
comparing catalyst proposals from different
catalyst vendors is a completely valid
evaluation technique. However, this is
flawed approach.
A typical catalyst proposal is the result
of a proprietary kinetic model developed
by an individual catalyst vendor. Although
most (if not all) kinetic models share the
same core principles (e.g., Langmuir-Hinshelwood
kinetics), each of them is unique
if you look further into the assumptions
and the details. Also, these kinetic models
are not 100% accurate, so they are likely
to yield different results despite the same
feed properties.
Secondly, the feed properties provided
by the refiner in the catalyst tender documents
are mostly incomplete, inconsistent
with each other or even over-specified. In
the authors' experience, a set of feed properties
is often a mix of data from various
sources (e.g., original design data plus past
operating data), as shown in TABLE 1.
It is not uncommon to see catalyst
vendors making certain feed assumptions
(typically based on institutional knowledge)
during the feed characterization
step (e.g., nitrogen, sulfur or aromatics
distribution). A catalyst vendor might
assume 35% of total nitrogen is basic nitrogen
for Middle Eastern crudes while
another uses 1/3 as an assumption. Which
number is more accurate? How can we
know if all catalyst vendors are adopting
the same assumptions? Additionally, a
typical crude diet is often a mix of various
crudes from all around the world, and
not only from a specific region. What if
South American or West African crudes
are dominant in the crude slate?
To add to the challenges, some catalyst
vendors are more aggressive than others
with their yield estimates. It must be remembered
that a catalyst vendor's priority
is to secure the sale. The authors have experienced
cases where it became apparent
that a catalyst vendor " tuned " its kinetic
model to produce yields for its proposal
that were more attractive. For example, a
diesel hydrotreating catalyst vendor once
proposed an almost nil offgas yield to a refiner
without justifying or explaining this
anomaly. When challenged, the catalyst
vendor just stated that it was the result of
the kinetic model. To add insult to injury,
the same catalyst vendor also proposed
a suspiciously aggressive diesel product
density (e.g., a much lower than usual diesel
density). Although the same catalyst
vendor later revised the new diesel density
because the refinery expressed strong disbelief
in the performance predictions, the
vendor did not make any changes in aromatic
contents in the diesel product and
overall hydrogen consumption. The illogical
revision was clear proof that this catalyst
vendor deliberately tuned the catalyst
performances presented in its proposal.
Without a reasonable explanation from
the catalyst vendor regarding the " too
good to be true " catalyst performance, the
refiner decided to negatively weigh the
results from the abovementioned catalyst
vendor due to the uncertainty over the
FIG. 1. The diesel hydrotreater is one of the
most important-yet-ignored refining units
when it comes to refinery catalyst testing.
Hydrocarbon Processing | DECEMBER 2022 35
Hydrocarbon Processing - December 2022
Table of Contents for the Digital Edition of Hydrocarbon Processing - December 2022
Hydrocarbon Processing - December 2022 - 1
Hydrocarbon Processing - December 2022 - 2
Hydrocarbon Processing - December 2022 - 3
Hydrocarbon Processing - December 2022 - 4
Hydrocarbon Processing - December 2022 - 5
Hydrocarbon Processing - December 2022 - 6
Hydrocarbon Processing - December 2022 - 7
Hydrocarbon Processing - December 2022 - 8
Hydrocarbon Processing - December 2022 - 9
Hydrocarbon Processing - December 2022 - 10
Hydrocarbon Processing - December 2022 - 10A
Hydrocarbon Processing - December 2022 - 10B
Hydrocarbon Processing - December 2022 - 11
Hydrocarbon Processing - December 2022 - 12
Hydrocarbon Processing - December 2022 - 13
Hydrocarbon Processing - December 2022 - 14
Hydrocarbon Processing - December 2022 - 15
Hydrocarbon Processing - December 2022 - 16
Hydrocarbon Processing - December 2022 - 17
Hydrocarbon Processing - December 2022 - 18
Hydrocarbon Processing - December 2022 - 19
Hydrocarbon Processing - December 2022 - 20
Hydrocarbon Processing - December 2022 - 21
Hydrocarbon Processing - December 2022 - 22
Hydrocarbon Processing - December 2022 - 23
Hydrocarbon Processing - December 2022 - 24
Hydrocarbon Processing - December 2022 - 25
Hydrocarbon Processing - December 2022 - 26
Hydrocarbon Processing - December 2022 - 27
Hydrocarbon Processing - December 2022 - 28
Hydrocarbon Processing - December 2022 - 29
Hydrocarbon Processing - December 2022 - 30
Hydrocarbon Processing - December 2022 - 31
Hydrocarbon Processing - December 2022 - 32
Hydrocarbon Processing - December 2022 - 33
Hydrocarbon Processing - December 2022 - 34
Hydrocarbon Processing - December 2022 - 35
Hydrocarbon Processing - December 2022 - 36
Hydrocarbon Processing - December 2022 - 37
Hydrocarbon Processing - December 2022 - 38
Hydrocarbon Processing - December 2022 - 39
Hydrocarbon Processing - December 2022 - 40
Hydrocarbon Processing - December 2022 - 41
Hydrocarbon Processing - December 2022 - 42
Hydrocarbon Processing - December 2022 - 43
Hydrocarbon Processing - December 2022 - 44
Hydrocarbon Processing - December 2022 - 45
Hydrocarbon Processing - December 2022 - 46
Hydrocarbon Processing - December 2022 - 47
Hydrocarbon Processing - December 2022 - 48
Hydrocarbon Processing - December 2022 - 49
Hydrocarbon Processing - December 2022 - 50
Hydrocarbon Processing - December 2022 - 51
Hydrocarbon Processing - December 2022 - 52
Hydrocarbon Processing - December 2022 - 53
Hydrocarbon Processing - December 2022 - 54
Hydrocarbon Processing - December 2022 - 55
Hydrocarbon Processing - December 2022 - 56
Hydrocarbon Processing - December 2022 - 57
Hydrocarbon Processing - December 2022 - 58
Hydrocarbon Processing - December 2022 - 59
Hydrocarbon Processing - December 2022 - 60
Hydrocarbon Processing - December 2022 - 61
Hydrocarbon Processing - December 2022 - 62
Hydrocarbon Processing - December 2022 - 63
Hydrocarbon Processing - December 2022 - 64
Hydrocarbon Processing - December 2022 - 65
Hydrocarbon Processing - December 2022 - 66
Hydrocarbon Processing - December 2022 - 67
Hydrocarbon Processing - December 2022 - 68
https://www.nxtbook.com/gulfenergyinfo/gulfpub/HPI-Market-Data-2023-v3
https://www.nxtbook.com/gulfenergyinfo/gulfpub/hpi-market-data-2024-v2
https://www.nxtbook.com/gulfenergyinfo/gulfpub/hpi-market-data-2024
https://www.nxtbook.com/gulfenergyinfo/gulfpub/gas-processes-handbook-2022_v2
https://www.nxtbook.com/gulfenergyinfo/gulfpub/gas-processes-handbook-2022
https://www.nxtbook.com/gulfenergyinfo/gulfpub/hp_202212
https://www.nxtbook.com/gulfenergyinfo/gulfpub/hpi-market-data-2023-v2
https://www.nxtbook.com/gulfenergyinfo/gulfpub/hpi-market-data-2023
https://www.nxtbook.com/gulfenergyinfo/gulfpub/hp_202211
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202210
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202209
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202208
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202207_v2
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202207
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202206_v2
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202206
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202205_v2
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202205
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202204_v2
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202204
https://www.nxtbook.com/nxtbooks/gulfpub/hp_032022
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202203
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202202
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202201
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202112
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202111
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202110
https://www.nxtbook.com/nxtbooks/gulfpub/hpimarket_2022_v2
https://www.nxtbook.com/nxtbooks/gulfpub/hpimarket_2022
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202109
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202108
https://www.nxtbook.com/nxtbooks/gulfpub/petrochemical_processes_handbook_2021_v2
https://www.nxtbook.com/nxtbooks/gulfpub/petrochemical_processes_handbook_2021
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202107
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202106
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202105
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202104
https://www.nxtbook.com/nxtbooks/gulfpub/hp_ebooks
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202103
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202102
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202101
https://www.nxtbook.com/nxtbooks/gulfpub/catalyst_handbook_2020_v2
https://www.nxtbook.com/nxtbooks/gulfpub/catalyst_handbook_2020
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202012
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202011
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202010
https://www.nxtbook.com/nxtbooks/gulfpub/hpimarket_2021
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202009
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202008
https://www.nxtbook.com/nxtbooks/gulfpub/refining_processes_handbook_2020
https://www.nxtbook.com/nxtbooks/gulfpub/refining_processes_handbook_2020_v2
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202007
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202006
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202005
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202004
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202003
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202002
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202001
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201912
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201911
https://www.nxtbook.com/nxtbooks/gulfpub/hpimarket_2020_v2
https://www.nxtbook.com/nxtbooks/gulfpub/hpimarket_2020
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201910
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201909
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201908
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201907
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201906
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201905
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201904
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201903
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201902
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201901
https://www.nxtbook.com/nxtbooks/gulfpub/petrochemical_2018_v2
https://www.nxtbook.com/nxtbooks/gulfpub/petrochemical_2018
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201812
https://www.nxtbook.com/nxtbooks/gulfpub/hpimarket_2019_v2
https://www.nxtbook.com/nxtbooks/gulfpub/hpimarket_2019
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201811
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201810
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201809
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201808
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201807
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201806
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201805
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201804
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201803
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201802
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201801
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201712
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201711
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201710
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201709
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201708
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201707
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201706
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201705
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201704
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201703
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201702
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201701
https://www.nxtbook.com/nxtbooks/gulfpub/hp_2017mediaplanner
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201612
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201611
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201610
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201609
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201608
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201607
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201606
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201605
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201604
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201603
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201602
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201601
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201512
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201511
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201510
https://www.nxtbook.com/nxtbooks/gulfpub/hp_2016mediaplanner
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201509
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201508
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201507
https://www.nxtbook.com/nxtbooks/gulfpub/hp_2015tmsd
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201506
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201505
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201504
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201503
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201502
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201501
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201412
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201411
https://www.nxtbook.com/nxtbooks/gulfpub/hp_2015mediaplanner
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201410
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201409
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201408
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201407
https://www.nxtbook.com/nxtbooks/gulfpub/hp_2014petrochemicalprocesses_v2
https://www.nxtbook.com/nxtbooks/gulfpub/hp_2014petrochemicalprocesses
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201406
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201405
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201404
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201403
https://www.nxtbook.com/nxtbooks/gulfpub/hp_2014calendar
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201402
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201401
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201312
https://www.nxtbook.com/nxtbooks/gulfpub/hp_2014mediaplanner
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201311
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201310
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201309
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201308
https://www.nxtbook.com/nxtbooks/gulfpub/hp_srsguide2013
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201307
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201306
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201305
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201304
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201303
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201302
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201301
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201212
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201211
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201210
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201209
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201208
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201207
https://www.nxtbook.com/nxtbooks/gulfpub/hp_srsguide2012
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201206
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201205
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201204
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201203
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201202
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201201
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201112
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201111
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201110
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201109
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201108
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201107_srsguide
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201107
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201106
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201105
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201104
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201103
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201102
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201101
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201012
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201011
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201010
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201009
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201008
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201007
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201006
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201005
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201004
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201003
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201002
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201001
https://www.nxtbook.com/nxtbooks/gulfpub/hp_200912
https://www.nxtbook.com/nxtbooks/gulfpub/hp_200911
https://www.nxtbook.com/nxtbooks/gulfpub/hp_200910
https://www.nxtbook.com/nxtbooks/gulfpub/hp_200909
https://www.nxtbook.com/nxtbooks/gulfpub/hp_200908
https://www.nxtbook.com/nxtbooks/gulfpub/hp_200907
https://www.nxtbook.com/nxtbooks/gulfpub/hp_200906
https://www.nxtbook.com/nxtbooks/gulfpub/hp_200905
https://www.nxtbook.com/nxtbooks/gulfpub/hp_200904
https://www.nxtbook.com/nxtbooks/gulfpub/hp_200903
https://www.nxtbook.com/nxtbooks/gulfpub/hp_200902
https://www.nxtbook.com/nxtbooks/gulfpub/hp_200901
https://www.nxtbookmedia.com