June
2016
HYDROCARBON
ENGINEERING
76
Q&A
Q
Explain why catalysts are so crucial to refining and
petrochemical operations.
Catalysts are of paramount importance to the refining and
petrochemical industries, since they allow operators to carry out a
desired reaction faster and more selectively than in a non-catalysed
manner, which has huge benefits in terms of economics (e.g., higher
desired product yield, less formation of unwanted byproducts, lower
operating costs through lower operating temperature and/or
pressure), energy efficiency and safety. Almost all refining and
petrochemical products are upgraded by at least one catalytic
reaction during their production process.
q
To what extent has the downstream catalyst market
grown over the past 10 years, and what have been the
driving factors?
The downstream catalyst market has grown substantially in recent
years, driven by several factors: firstly, an increase in global demand
for refined products, mainly due to an increase in transportation fuels
demand (gasoline and diesel), and for petrochemicals. Secondly, the
specifications for transportation fuels have been tightened all around
the world, with more and more countries requiring ultra low sulfur
levels. Finally, the demand has increased mostly for light products and
middle distillates, whereas the global crude offer has become heavier,
which has resulted in an increased demand for conversion catalysts.
q
How have catalysts changed since your company began
operating in the industry?
Axens has successfully operated in the industry for more than
60 years through its mother companies IFPEN and Procatalyse, and
its catalysts have considerably evolved in order to reach the targets
of higher activity and stability, improved cost efficiency and lower
environmental impact. All aspects of catalyst design have been
optimised, from carrier composition, texture and shape to active
metals formulation. Since Axens invests a substantial portion of its
revenue in catalyst research and development (R&D), it can offer
some of the best catalysts available, and intends to continue this in
the future.
q
What are the main applications for your company’s
catalysts or catalyst technologies within the refining
and petrochemical industries?
Axens offers one of the widest catalysts and adsorbents portfolios to
the refinery and petrochemical industries, ranging from clean fuels
production over conversion solutions to aromatics production and
olefins purification. This may allow operators to benefit from Axens’
commercially highly attractive bundle offers.
For hydrotreating, Axens has launched Impulse
TM
, a complete,
high performance family of hydrotreating catalysts combining high
stability with outstanding activity levels. Impulse catalysts achieve
high performance through maximising the amount of the catalytically
most active mixed Mo/Ni and Mo/Co sites by optimising promotion,
metal dispersion and support characteristics.
For hydrocracking, catalysts from the pretreating HRK series and
the hydrocracking HDK and HYK series are combined to achieve
operator’s conversion targets. The combination of the HRK, HDK and
HYK series enables operators to squeeze more middle distillates from
vacuum gas oil and heavy fractions, while reaching high conversion
levels and product quality.
Symphony
TM
is the latest generation family of reforming catalysts,
combining the best in catalyst support and multi-metal formulation
technologies. Compelling results are achieved for virtually all
reforming services: from fixed bed to continuous catalyst regeneration
(CCR), low to high density loading, lean to rich naphtha feed and high
to low octane severity. Contrasted with prior generation, best in class
reforming catalysts, Symphony catalysts show step out improvements
in yield, selectivity, coke stability and hydrothermal stability without
sacrificing activity, leading to a notable increase in unit profitability.
For olefins purification, the LD series catalysts are a market leader
for all liquid phase selective hydrogenation reactions, including the
purification of C
3
, C
4
, C
5
streams and pygas.
For sulfur recovery, Axens has pioneered the use of titanium
dioxide catalysts to boost Claus units efficiency and has
revolutionised the design of Claus tail gas treatment units by
introducing low temperature catalysts. Axens’ current portfolio ranges
from regular Claus alumina, boosted alumina for carbonyl sulfide
(COS) hydrolysis, pure titanium dioxide catalysts, benzene, toluene
and xylene (BTX) management catalysts and tail gas treatment
catalysts.
To purify many different gas and liquid streams, Axens offers a
wide range of molecular sieves, specialty aluminas and guard beds of
the AxSorb
TM
and AxTrap
TM
families.
The company also offers a wide and flexible catalyst management
service, Orchestra
TM
, delivering several benefits: reduced catalyst
change out costs while meeting guaranteed technical performances;
increased unit utilisation rate through optimised management of
turnarounds and operations; and maximised and sustainable used
product valorisation.
On top of this, the company as a licensor provides cutting edge
technologies, along with highly efficient equipment and profitability
boosting consulting services. This combination provides a unique
single source offering, enabling Axens to respond efficiently and
rapidly to all customer needs.
Q
What is the next 'big thing' in the downstream catalyst
market?
The refining sector faces a double challenge: provide an increasing
amount of ever-cleaner fuels, and find sources that do not rely on
crude oil and allow for a minimised environmental footprint (reduced
greenhouse gas emissions all along the lifecycle). Axens has developed
catalysts and technology to face these challenges, e.g., through the
hydroprocessing of vegetable oils or animal fats yielding ultra clean
middle distillates (Vegan
TM
), or through the conversion of synthesis
gas of various origins (natural gas, biomass) into waxy materials that
are hydrocracked into ultra clean liquid fuels (Gasel
TM
). In the field of
petrochemicals, bio-ethylene can be produced via dehydration of
renewable bio-ethanol (Atol
TM
).
ARNO FRITZ, AXENS
Impulse
TM
catalyst technology.
