Catalysts in Refining Processes

Course Content

• CHARACTERISTICS & PROPERTIES OF INDUSTRIAL CATALYSTS

  • Main types of catalytic processes and related catalyst markets in the refining and heavy petrochemical industries.
  • Main features of catalysis:
  • Thermodynamics in a chemical reaction. Kinetics in heterogeneous catalysis.
  • Quality requirements for an industrial catalyst, characterization of its properties.
  • Processes for catalyst synthesis and industrial manufacture of catalysts.

• OPERATION & PERFORMANCE CONTROL OF INDUSTRIAL CATALYSTS

  • The following items are covered for each refining unit: process and chemical reaction characteristics, selection and developments of catalytic formula, catalyst implementation, process flow diagram; process performances and catalyst monitoring. The specific features for the corresponding type of catalyst are emphasized.
  • Catalytic reforming catalysts:
  • Precautions for start-up, monitoring and maintaining catalyst activity, incidents. Regeneration steps.
  • Catalytic formulas for the regenerative process.
  • Solution for benzene removal.
  • Isomerization catalysts:
  • Different types of catalysts and process arrangement. Impact on the resulting octane number.
  • Influence of poisons; operational constraints linked to the type of catalyst.
  • Catalytic cracking catalysts:
  • Zeolite structure and design for yield optimization.
  • Analysis of catalyst ageing.
  • Improvements of LCO and propylene yields.
  • Improvements in catalyst regeneration. Metal passivation and solutions for vanadium effects.
  • Additives for emission reduction; adaptation for residue treatment.
  • C₃/C₄ Alkylation catalysts:
  • Mechanisms of liquid homogeneous HF and H₂SO₄ catalysis.
  • Process performance and particular constraints.
  • Hydrotreatment and hydrocracking catalysts:
  • Active phase structure, sulfiding at start-up.
  • Specific issues in treating unsaturated cuts from coker, visbreaker and FCC.
  • Evolution of catalytic formulas and processes for heavy cuts and residue hydrotreatment.
  • Selective hydrotreatment of FCC gasolines minimizing octane loss.
  • Adaptation of catalytic formulas for heavy feedstock hydrocracking.
  • Catalysts for Claus converter and tail gas treatment:
  • Claus catalysts. Impact of sulfur deposition and temperature on conversion.
  • COS and CS₂ hydrolysis. Deactivation and regeneration.
  • Adaptation to tail gas treatment processes.

• IMPLEMENTATION & LIFE CYCLE OF CATALYSTS

  • Precautions in the transport and the manipulation of catalysts.
  • Follow-up of performances, from the start-up to the regeneration; metals recovery.

• VISIT OF TEST AND PILOT FACILITIES OF IFP Energies nouvelles

  • Different stages of testing at micro-pilot, pilot and semi-industrial scale.