Your Professional FCC Pretreatment Catalyst Supplier
We supply hydrorefining catalysts for FCC pretreatment and other refinery feed pretreatment applications. Our catalyst portfolio includes Co-Mo, Mo-Ni and Mo-W-Ni systems supported on alumina or modified support materials, with catalyst properties available in different combinations of active-metal loading, pore structure, surface area, bulk density, particle shape and mechanical strength.
For FCC pretreatment service, catalyst selection is based on the actual feedstock and reactor conditions rather than catalyst composition alone. We evaluate requirements such as feed sulfur and nitrogen, density, boiling range, metals and contaminants, hydrogen partial pressure, liquid hourly space velocity, operating temperature, cycle target and required product quality before recommending a suitable catalyst grade.
Supplementary Technical Specifications Matrix
|
Technical Parameter |
Co-Mo System (XDH-2) |
Mo-Ni System (PV-20) |
Mo-W-Ni System (XDH-3) |
|
Active Components (Oxide Basis) |
MoO3: 10.0 - 18.0 wt% CoO: 2.0 - 5.0 wt% |
MoO3: 12.0 - 20.0 wt% NiO: 2.5 - 6.0 wt% |
MoO3 + WO3: 15.0 - 25.0 wt% NiO: 3.0 - 7.0 wt% |
|
Support Base & Purity |
Modified gamma-Al2O3 Na2O <= 0.05 wt% |
Specialized Alumina Support Na2O <= 0.05 wt% |
Modified gamma-Al2O3 Na2O <= 0.05 wt% |
|
Surface Area |
150 - 280 m2/g |
160 - 270 m2/g |
140 - 250 m2/g |
|
Pore Volume |
0.40 - 0.65 cm3/g |
0.38 - 0.60 cm3/g |
0.35 - 0.58 cm3/g |
|
Bulk Density |
0.55 - 0.78 g/cm3 |
0.58 - 0.82 g/cm3 |
0.60 - 0.85 g/cm3 |
|
Side Crushing Strength (SCS) |
>= 120 N/cm |
>= 125 N/cm |
>= 130 N/cm |
|
Particle Geometry |
Cylinder (1.2 - 2.0 mm) / Trilobe |
Cylinder (1.2 - 2.0 mm) / Trilobe |
Cylinder (1.2 - 2.0 mm) / Trilobe |
|
Attrition Loss |
<= 0.5 wt% |
<= 0.5 wt% |
<= 0.5 wt% |
FCC Pretreatment Applications
FCC pretreatment catalysts are used upstream of FCC units where refinery feedstocks require hydrotreating before catalytic cracking. Typical evaluation areas include:
VGO Hydrotreating
Vacuum gas oil is a major FCC feedstock. Pretreatment can be used to reduce sulfur and nitrogen compounds and improve feed quality before the VGO enters the FCC unit.
Cracked Feed Pretreatmen
Cracked gas oils and other secondary refinery streams can contain more difficult sulfur and nitrogen compounds and may require different catalyst activity and stability characteristics.
FCC Feed Quality Improvement
Hydrotreating upstream of FCC can change the quality of the feed entering the cracking unit, connecting pretreatment performance directly with downstream cracking objectives.
Proper handling and in-situ loading procedures ensure uniform liquid distribution and prevent channeling or localized overheating during refinery startup.
Dense vs. Sock Loading: Selection of the loading method depends on reactor diameter, bed depth, and target void fraction to minimize pressure drop.
Pre-wetting and Sulfiding: Guidance on startup procedures, drying protocols, and ex-situ or in-situ activation/sulfiding requirements to achieve full active metal conversion.
Pressure Drop Management: Monitoring differential pressure across the catalyst bed during initial startup and regular operation cycles.
How to Select an FCC Pretreatment Catalyst
A practical catalyst selection process starts with the refinery's operating data.
Feedstock Assessment
Provide the available feed assay, including sulfur, total nitrogen, basic nitrogen, density, distillation range, Conradson carbon, metals such as nickel and vanadium, and aromatics.
Reactor Conditions
Review operating temperature, total pressure, hydrogen partial pressure, liquid hourly space velocity, hydrogen-to-oil ratio, reactor volume, existing catalyst loading, number of catalyst beds, and expected cycle length.
Performance Target
Define the actual target instead of requesting a generic high-activity catalyst, such as specific sulfur reduction, nitrogen reduction, cycle length, or hydrogen consumption constraints.
Catalyst Specification
Match the process conditions against active metal systems, support structures, surface area, pore volume, bulk density, crushing strength, and particle shape.
Troubleshooting & Deactivation Diagnostics
Understanding common operational anomalies helps refiners identify whether performance drop is driven by process upsets or catalyst aging:
Rapid Pressure Drop Buildup: Typically caused by particulate carryover, iron scale accumulation at the reactor inlet, or excessive fines generation due to poor mechanical strength or improper loading techniques.
Thermal Runaway or Hot Spots: Caused by maldistribution of gas and liquid phases, poor initial catalyst wetting, or localized channeling within fixed-bed reactors.
Accelerated Activity Loss: Often results from heavy metal poisoning, severe hydrogen starvation, or operating outside the designed temperature and space velocity window.
Manufacturing and Quality Control
Hydrorefining catalyst production is supported by dedicated catalyst production lines, process control systems, and physical/chemical testing facilities. The manufacturing infrastructure currently operates three catalyst production lines with a total annual capacity of approximately 9,500 tons of various catalysts. A distributed control system records production-process history, monitors operating variables and identifies abnormal process conditions.
The manufacturing and quality-control process covers key steps:
Raw-material control and verification
Support preparation and formulation
Active-component impregnation and loading
Forming, drying, and calcination
Physical and chemical property testing
Batch inspection and packaging evaluation
For hydrorefining catalyst grades, testing procedures cover surface area, pore volume, bulk density, crushing strength, and chemical composition. Hydrorefining catalysts are available in jumbo bags or steel-drum packaging according to project requirements.
FAQ
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