How Should You Conduct an FCC Catalyst Study?
An FCC catalyst study can be conducted as either a paper study or a laboratory test. Paper studies compare supplier projections, while lab studies test catalysts directly with your feed. The right approach depends on your unit’s constraints, objectives, and resources.
Becht’s Fun with FCC Catalyst series takes a conversational look at how catalyst choices shape FCC performance. From tweaking frequency to test strategy and cost trade-offs, each post aims to spark debate and share real-world insights – because great ideas often start with great discussions.
Key takeaways
- FCC catalyst studies can be conducted as paper evaluations or laboratory tests.
- Paper studies rely on supplier data and assume the feedstock is not unique.
- Lab studies test catalysts with actual feed and metals content (Ni and V).
- Accelerated lab deactivation protocols may exaggerate catalyst performance differences.
- The best study approach depends on unit constraints, objectives, and budget.
Two paths to catalyst selection
There are options to consider when you decide to conduct an FCC catalyst study. In our previous article, we discussed what you’ll need to have ready before you conduct a study. Once you finish this preparation, you can choose two different paths for evaluating potential catalysts to improve your profits: paper studies and lab studies.
Paper studies for FCC catalyst evaluation
Paper studies are usually your best option if you lack a testing lab of your own or just don’t believe the lab study is worth the cost. Here are a few pros and cons.
Pros of a paper study:
- Requires you to look at the unit operation and consider how it can be improved
- Allows you to reach out and communicate with all of the suppliers
- Gives you a good opportunity to hear about recent catalyst advances
- Lets the suppliers know you want them to compete for your business
Cons of a paper study:
- Assumes your feed is not unique
- Doesn’t verify supplier performance claims for your specific feed and constraints
- Paper yield estimate will very likely state that the proposed catalyst is better than your incumbent, as all suppliers believe their catalyst is the best
Lab studies for FCC catalyst evaluation
Laboratory testing typically consists of some sort of catalyst deactivation method followed by testing in an ACE unit or circulating pilot plant. Here are a few pros and cons.
Pros of a lab study:
- Allows for direct comparison of the proposed catalysts with your feed
- Can be used to evaluate how each catalyst will tolerate feed metals (usually Ni and V)
- Can provide a deactivation rate for each catalyst, which is critical for predicting fresh catalyst additions
- Gives you the data you need to build a model test case
Cons of a lab study:
- Costs money to conduct the study, typically ranging from $50K-$300K depending on how you conduct it
- Often exaggerate differences between the catalysts due to accelerated deactivation protocols that do not produce a “true” ecat. Unit ecat is a blend of very fresh and very old catalyst, but most deactivation protocols give you one homogeneous sample
- ACE testing has extended residence time where the catalyst is exposed to feed, which tends to favor catalysts with higher zeolite surface area
- Circulating pilot plants typically have longer riser and stripper residence times than your unit. Coke yield differences should be heavily discounted
Choosing the right catalyst study approach for your FCC unit
The bottom line is that paper studies and pilot plant studies are both useful in different situations. Becht has experience leading and supporting catalyst studies across a wide range of units and operating objectives. Because we are technology-agnostic, our role is to help you design the right study, ask the right questions, and objectively evaluate the results.
If you’re looking for an independent resource to help guide your catalyst evaluation and maximize the value of your study, reach out to Becht’s FCC Process Technology Lead, Ally McNamara, to connect with one of our FCC subject matter experts. Let’s talk about how we can help you conduct your upcoming catalyst study!
