The Catalyst Review November 2024 - 3

Independent Perspective
The views expressed are those of the individual author and may not reflect those of The Catalyst Review or TCGR.
Catalytic Innovations Maximize Octane Production and Plastic Recycling
By Stephany Romanow
Refiners, petrochemical operators, and technology licensors gathered at the October 2024 AFPM Summit in New Orleans. This
technology-focused forum investigates issues affecting the refining and petrochemical industries. Here are several new catalytic
developments presented at the 2024 AFPM Summit.
Maximize FCC Profitability
The fluid catalytic cracking unit (FCCU) is the heart of the modern refinery and the primary LPG olefins source. Due to new vehicle
fuel-efficiency requirements, refiners are under pressure to produce higher octane gasoline. Consequently, processing strategies
must shift FCC operations to yield more butylene (C4=) and support alkylation units while reducing propylene (C3=) production.
Nik Larsen, FCC Technology Manager, Marathon Petroleum Company (MPC), and Grant Severyn, Technical Service Specialist,
BASF Corporation, addressed the C4= and octane problems. In their AFPM presentation, MPC and BASF shared their collaboration
on exploring new catalysts to resolve the C4= dilemma.
Following successful pilot-plant testing, MPC conducted trial runs of BASF's new FCC catalyst, Fourtiva™, to increase C4=
selectivity. MPC used BASF's Fourte™ FCC catalyst system and LPG olefin additives as the base case. In particular, MPC performed
rigorous commercial trials at eight of its FCCUs.
MPC's demonstration trials had specific processing goals and included:
● Raising total LPG olefin yields
● Producing more C4= over C3=
● Reducing delta coke make
● Increasing naphtha octane
The test runs used vacuum gasoil with low-metals content, and some used LPG olefin additives. In addition, the trial runs investigated
varied feedstock qualities encountered over summer and winter operating modes.
MCP's Larsen confirmed that the Fourtiva™ demonstration results achieved all design objectives and delivered significant value
across the company's refining network. In addition, the new catalyst enabled reducing LPG olefin additive usage at multiple sites
while maintaining alkylation operations at full capacity.
" Our collaboration with Marathon during the new product launch enabled BASF to rapidly meet their needs for improved butylene
selectivity and yields and higher naphtha octane. Fourtiva's success in Marathon's refining network showcases our shared
commitment to advancing FCC catalyst technology, " said BASF's Grant Severyn.
Circularity within Refinery Operations
In addition to reliability and safety,
the 2024 AFPM Summit addressed
sustainability and circularity issues.
According to Ketjen Corporation,
refineries have unique positions
topursue circularity opportunities.
Barbara Slettenhaar, Global
Business Director, Ketjen
Corporation, emphasized that the
company's Clean Fuel Technology
Group continues researching
advanced processing technologies
and
catalyst
modeling
for
renewable fuels and feedstocks.
In addition, these efforts focus on
co-processing waste plastics (WP)
into monomers, fuels, and chemicals (Figure 1).
Why is co-processing WP so difficult? WP oil (WPO) is a diverse mixture of polymers, additives, and contaminants. These properties
cause operating challenges, including wide boiling point distribution, chemical reactivity, and processing instability problems.
Consequently, WPOs require pretreatment before usage as refinery feedstreams.
At the 2024 AFPM Summit, Aline Bueno Curry, Technical Specialist, Ketjen Corporation, discussed how hydroprocessing solutions
use molecular modeling to achieve circularity. WPO cleanup involves robust hydroprocessing technologies, catalysts, and
guard-bed systems. The polished product is suitable for co-processing by steam cracking or FCCUs.
Figure 1. Recycling waste plastics involves thermal, hydroprocessing, and catalytic processes.
Source: Ketjen Corporation.
The Catalyst Review
November 2024
3

The Catalyst Review November 2024

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