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Catalagram®
A Refining Technologies Publication
Issue No. 107 / 2010 / www.grace.com
In this issue
• GENESIS® Catalyst Commercial Update
• Distillate Pool Maximization by Additional Hydroprocessing
• Salt Deposition in FCC Gas Concentration Units
• CP® P - Third Generation Low NOx CO Promoter
Dear Refiners,
The current refining atmosphere in North American and
Europe is the most difficult in over a quarter century.
Declining utilization rates, narrow light-heavy differentials,
and weak demand for transportation fuels has meant
steeply declining profitability for refiners.
As the leading supplier of FCC catalysts and additives,
Grace Davison is dedicated to helping you navigate this
turbulence. Our investment in world-class research and
development to constantly invent new products and fine-
tune existing ones continues strong in this challenging
environment. With our flexible technology base and broad
manufacturing capabilities, we deliver the catalyst solu-
tions you need to be profitable and the value you deserve.
This issue of the Catalagram®
highlights the successful application flexibility of our GENESIS®
solutions to our
customers' challenge of the need to react quickly to changing supply/demand dynamics. These catalysts have
been custom blended in 80 applications for over 50 refineries worldwide. As product slate demand changes,
GENESIS®
catalyst in the unit can be reformulated to maximize profitability and capture short term economic
opportunities. To speed implementation, formulation adjustment can take place in the fresh hopper, minimizing
the delay often associated with a catalyst change out.
We also introduce our third generation non-platinum low NOx CO promoter, CP®
P. Our newest CO promoter
delivers quick CO/afterburn response, equivalent to traditional platinum formulated promoters, and up to 20%
lower NOx emissions compared to competitive products.
On the immediate horizon, we introduce our new products AsteraTM
and AlcyonTM
. Units that are circulation limit-
ed can’t take full advantage of improved feed quality. When the FCC catalyst is not active enough regenerator
temperatures become too low and desired reactor temperatures can’t be achieved. Some refiners resort to
burning torch oil or recycling slurry to provide additional delta coke which is often detrimental to the operation.
With its novel, unconventional silica-alumina binder, AsteraTM
FCC catalyst not only delivers excellent value but
will improve your yield slate and reliability. Best of all, AsteraTM
will lower your daily catalyst cost. AlyconTM
is a
revolutionary new FCC catalyst designed for the maximum activity needed to process hydrotreated feeds. Look
for more information from us in the coming months.
Our responsibility to our refining customers is the core of our business. We pledge to continue developing the
products and services that will maximize your profitability in all economic climates.
Joanne Deady
Vice President, Global Marketing
Grace Davison Refining Technologies
A MESSAGE FROM THE EDITOR...
GRACE DAVISON CATALAGRAM 1
Managing Editor Joanne Deady and Technical
Editor Rosann Schiller
04 Grace Davison’s GENESIS®
Catalyst Systems
Provide Refiners the Flexibility to Capture
Economic Opportunities
By Rosann K. Schiller
GENESIS®
is one of Grace Davison’s most successful catalysts,
with 20% of the world’s FCC capacity, having utilized the technology.
GENESIS®
systems offer refiners formulation flexibility and the ability
to realize the desired yield shifts quickly in order to capture dynamic
economic opportunities.
13 Development of Next Generation Low NOx
Combustion Promoters Based on New
Mechanistic Insights
By Eric Griesinger, Mike Ziebarth and Uday Singh
Grace research and development efforts have led to the develop-
ment of CP®
P, a new low NOx combustion promoter. Data from
multiple field trials has indicated excellent CO control with quick
response to afterburn and/or CO excursions, like traditional Pt-
based promoters. However, unlike traditional promoters, CP®
P pro-
vides lower NOx emissions and very quick NOx emission decay
periods.
22 Distillate Pool Maximization
by Additional LCO Hydroprocessing
By Brian Watkins, David Krenzke and Charles Olsen
Advanced Refining Technologies®
has developed catalysts specifi-
cally designed to handle more difficult feeds exemplified by the
SmART Catalyst System®
technology for ULSD. This technology
has been widely accepted, with over 75 units in commercial service
since its inception. ART continues to improve its line of ultra high
activity ULSD catalysts with the addition of an SRO catalyst.
34 Salt Deposition in FCC Gas Concentration
Units
By Michel Melin, Gordon McElhiney and Colin Baillie
Various operational problems can arise when salt deposition occurs
in FCC gas concentration units. Grace Davison Technical Service
troubleshoots users of alumina sol catalysts to manage and solve
any issues of ammonium chloride deposition.
IN THIS ISSUE
Catalagram 107
ISSUE No. 107 / 2010
Managing Editor:
Joanne Deady
Technical Editor:
Rosann Schiller
Contributors:
Colin Baillie
Eric Griesinger
David Krenzke
Gordon McElhiney
Michel Melin
Charles Olsen
Rosann Schiller
Uday Singh
Brian Watkins
Mike Ziebarth
Please address your comments to:
betsy.mettee@grace.com
Grace Davison Refining
Technologies
Advanced Refining Technologies
7500 Grace Drive
Columbia, MD 21044
410.531.4000
www.e-catalysts.com
www.grace.com
www.artcatalysts.com
© 2010
W. R. Grace & Co.-Conn.
Catalagram®
A Refining Technologies Publication
Issue No. 107 / 2010 / www.grace.com
In this issue
• GENESIS® Catalyst Commercial Update
• Distillate Pool Maximization by Additional Hydroprocessing
• Salt Deposition in FCC Gas Concentration Units
• CP® P - Third Generation Low NOx CO Promoter
GRACE DAVISON CATALAGRAM 13
Eric Griesinger
Product Manager
Environmental Additives
Grace Davison
Refining Technologies
Columbia, MD
Mike Ziebarth
Manager
Synthesis Research
Grace Davison
Refining Technologies
Columbia, MD
Udayshankar G. Singh
Research & Development
Engineer
Grace Davison
Refining Technologies
Columbia, MD
The use of low NOx combustion
promoters in FCC units has
increased in recent years due to
stricter NOx emission limits and
implementation of EPA consent
decrees. Further, the recent EPA
issued final amendments to its
New Source Performance
Standards for Petroleum
Refineries indicate that additives
are now included as Best
Demonstrated Technology in the
reduction of FCCU NOx emis-
sions. Studies to determine
mechanisms by which low NOx
promoters reduce NOx, as well
as determining the FCCU operat-
ing parameters that effect NOx
formation are the focus of this
paper. A lab scale regenerator
test unit was used to study the
combustion of coked ecat at con-
ditions that closely simulate the
regenerator of an FCCU. This
unit was used to explore the
impact of certain regenerator
variables, including excess O2
level and type of combustion pro-
moter on CO and NOx emis-
sions. In addition, fixed bed
reactor experiments were carried
out to study the oxidation of
reduced nitrogen species on plat-
inum (Pt) and non-Pt based com-
bustion promoters to help
elucidate mechanistic differences.
Development of Next Generation
Low NOx Combustion Promoters
Based on New Mechanistic Insights
14 ISSUE No. 107 / 2010
Based on this improved mecha-
nistic understanding of how low
NOx combustion promoters work,
a new combustion promoter has
been developed. Commercial
field trials show excellent results.
Background
FCC units account for about
10% of the nitrogen oxide emis-
sions generated by stationary
sources in the United States.
These NOx emissions are the
result of nitrogen impurities in
the feed depositing on the cata-
lyst during the cracking reaction.
When the coke is burned off in
the regenerator, a portion of the
nitrogen is converted into NOx.
Since NOx emissions are a con-
tributor to acid rain, precursors in
the formation of ground level
ozone, and contribute to respirato-
ry health impacts, the EPA and
various state and local agencies
have been tightening NOx emis-
sion standards over the last
decade1,2.
A variety of NOx reduction
options, both catalytic and hard-
ware oriented, are available to
refiners to comply with limits on
NOx content emitted from the
FCCU regenerator flue gas
stream. One of the best meth-
ods of meeting these regulations
is the use of low NOx combus-
tion promoters. This method
has the advantage of being
simple and inexpensive since it
replaces traditional Pt-based
promoter, and also typically
requires no additional infrastruc-
ture or chemical reactants. In
addition, the U.S. Environmental
Protection Agency concluded
that newly adopted emission
limits utilizing additives and
combustion controls were
achievable, cost effective and
had fewer secondary impacts
than more costly hardware ori-
ented control technologies3.
The U. S. EPA issued final
amendments to its New Source
Performance Standards for
Petroleum Refineries (NSPS)3
on June 24, 2008. Within this
amendment, the EPA states that
the currently Best Demonstrated
Technology (BDT) to NOx emis-
sion control now includes the
use of additives in conjunction
with an upwardly revised NOx
emission limit of 80 ppmv based
on a 7-day rolling average.
Typically, under EPA Consent
Decree proceedings, FCCU
operations have been restricted
to a NOx emission limit of 20
ppmv based on a 365-day rolling
average and 40 ppmv based on
a 7-day rolling average. This
NSPS amendment now also rec-
ognizes the secondary environ-
mental impact that many of the
hardware solutions inflict upon
the environment, inherent in
their operation to achieve a 20
ppmv maximum NOx emission
limit. These secondary impacts
include PM (Particulate Matter)
as well as additional SO2 and
NOx emissions resulting from
increased electrical demand. In
addition, many of the hardware
solutions require supplementary
chemical reactants that add haz-
ards and emission problems of
their own1. As such, non-plat-
inum formulated oxidation pro-
moters and advanced oxidation
controls typically are anticipated
to provide the least overall envi-
ronmental impact, as they gen-
erally do not generate further
secondary environmental emis-
sions.
Even though there are many
advantages for the use of low
NOx promoters, there are some
limitations, especially with first
generation promoters. These
include variable and at times lim-
ited NOx reduction and also
occasionally low CO combustion
activity. The variability is thought
to be due to the wide range of
unit FCCU operating conditions,
as well as the variety of regener-
ator configurations. The pur-
pose of this paper and the R&D
work at Grace is to understand
the reactions behind NOx forma-
tion and destruction so improved
additives can be developed that
are more effective and less vari-
able in their performance. In
addition, work is on-going to
understand the operating condi-
tions that affect NOx formation in
order to develop recommenda-
tions to help refiners optimize
their unit to minimize NOx.
NOx Emission Mechanism
NOx in the FCC regenerator
originates from feed nitrogen
being deposited on the catalyst
as coke. When the nitrogen
containing coke is burned off in
the regenerator, about 10% of
the nitrogen is emitted as NOx
and the remainder is emitted as
nitrogen. Thermal NOx, which
results from the oxidation of
molecular nitrogen (N2), is not a
significant source of NOx at FCC
regenerator temperatures. This
has been shown to be the case
both by thermodynamic calcula-
tions and experimentally by per-
forming a nitrogen mass balance
around an FCC pilot plant unit4,5.
During the combustion of coke,
data indicates that the nitrogen
in the coke is first released as N2
or as a reduced nitrogen com-
pound, such as HCN. In the
presence of water vapor, gener-
ated by the combustion of coke,
the HCN is hydrolyzed to NH36,7.
These reduced nitrogen species
are then further oxidized to
GRACE DAVISON CATALAGRAM 15
Coke
Nitrogen
Reduced Nitrogen Species
(NH3, HCN)
NOx + Reductant
Nitrogen
(2B)
(2A)
(1)
Figure 1
Major NOx Reduction Pathways
either N2 or NOx. The NOx is
almost exclusively in the form of
NO. Once the NOx is formed it
can also react with various
reductants, such as carbon or
CO to form nitrogen.
In full burn units, traditional Pt-
based combustion promoters are
very effective at reducing CO but
also dramatically increase NOx
emissions. Low NOx combus-
tion promoters were introduced
to solve this problem by retain-
ing the CO oxidation function but
eliminating the sharp increase in
NOx. The low NOx combustion
promoters typically contain non-
Pt noble metals, potentially other
transition metals, and have mod-
ified alumina supports that help
with the NOx reduction func-
tion8,9,10.
Based on the reaction pathway
illustrated in Figure 1 for the for-
mation and destruction of NOx,
there are two major pathways by
which low NOx combustion pro-
moters can lower NOx. The first
(1) is catalyzing the reduction of
NOx to nitrogen. The second (2)
is acting on the NOx precursor
and minimizing its conversion to
NOx. This would be accom-
plished by promoting the oxida-
tion of the reduced nitrogen
species to nitrogen (eqn. 2A)
rather than to NOx (eqn. 2B).
Equation 2A
4NH3 + 3O2 = 2N2 + 6H2O
Equation 2B
4NH3 + 5O2 = 4NO + 6H2O
The first mechanism (1) has
been shown to be facilitated by
Grace combustion promoters.
This work is outlined in two
papers Grace published jointly
with researchers at the
University of South Carolina11,12.
The data indicated that additives
promoted the reduction of NO by
CO through an isocyanate inter-
mediate stabilized by the surface
of the low NOx combustion pro-
moter. The second mechanism
(2), involving the oxidation of
reduced nitrogen species to
NOx, is the subject of work in
this paper. The research eluci-
dating these mechanisms and
the development of new Grace
low NOx combustion promoters
was carried out in a fluidized
bed Regenerator Test Unit as
well as in a fixed bed reactor, as
described below.
Experimental
Regenerator Test Unit
A laboratory scale Regenerator
Test Unit (RTU) was utilized to
test the performance of low NOx
combustion promoters and con-
ditions that affect NOx emissions
in the FCC regenerator13. The
RTU simulates an FCC regener-
ator by feeding coked catalyst
onto the top of a fluidized bed
where the coke is burned off
under controlled conditions.
Catalyst is also constantly
removed, generating an equili-
brated catalyst ranging from
completely coked to completely
regenerated catalyst in the reac-
tor. This closely replicates an
actual FCC regenerator environ-
ment where additive perform-
ance can be determined and
where regenerator conditions
can be systematically changed
to determine their effect on NOx
emissions.
The additives were tested after a
metals-free Cyclic Propylene
Steam (CPS) deactivation. The
commercial FCC catalyst used in
the study was steam deactivated
for 4 hours at 1500ºF in 100%
steam. After deactivation, it was
coked in Davison Circular Riser
pilot plant using an FCC feed
that contained 0.18 wt.% total
nitrogen, 0.42 wt.% sulfur, and
5.1 wt.% Conradson carbon.
The coked catalyst contained
approximately 1 wt.% coke. For
testing purposes, the deactivat-
ed additive was blended with the
coked catalyst at a 0.2 wt.%
level. During testing the reactor
temperature was maintained at
700ºC, and the excess oxygen
was controlled at 1.1%. Data
were collected for 60 to 90 min
after the steady state was
achieved.
Fixed Bed Reactor
Fixed bed reactor work was car-
ried out, in collaboration with
University of South Carolina14, to
compare the oxidation of the
reduced nitrogen species over a
variety of noble metals on a low
NOx combustion promoter base
support. Ammonia was used as
the model compound due to its
availability, relatively low toxicity
and belief that it is a major inter-
mediate species in the formation
of NOx. The metals were
deposited on the support using
soluble metal salts and impreg-
nating to incipient wetness. The
catalysts were dried and then
calcined. The oxidation of
ammonia in the presence of oxy-
gen was carried out at 700ºC to
simulate a typical FCC regenera-
tor temperature. For each
experiment 0.2 grams of additive
was blended with 3 grams of
quartz in the fixed bed. Prior to
analysis, the samples were treat-
ed in a 10% O2/He flow at
700ºC. The ammonia feed gas
concentration used for the reac-
tion was 500 ppm. The testing
was carried out using oxygen
levels of 500 ppm and 2000
ppm. The data were collected
under steady-state conditions at
constant gas hourly space veloc-
ity (GHSV) of 30 L/gm/hr. The
reaction products from the reac-
tor were fed to a GC-mass spec-
trometer for identification and
quantification.
Results
The oxidation of ammonia to
NOx and N2 was carried out
over the low NOx combustion
promoter support as well as for
each of the supported metals.
The low NOx combustion pro-
moter support was considered
the base line and additional con-
version considered due to the
effect of the metal. The data in
Figure 2, for the 2000 ppm O2
case shows that the Pt-based
promoter converts a significantly
higher percentage of ammonia
into NOx than either noble metal
#1 or #2. The noble metal #1
catalyst is the most selective for
converting NH3 to N2 followed by
noble metal #2 catalyst. These
results indicate that the selectivi-
16 ISSUE No. 107 / 2010
40
50
60
70
0
10
20
30
Pt Metal #2 Metal #1
Noble Metals
NOxFormation(%)
Figure 2
NOx Formation vs. Noble Metal Type
ty of the combustion promoter in
catalyzing the oxidation of
reduced nitrogen species to
either N2 or NO is a key differ-
ence between the performance
of Pt and non-Pt promoters in
the FCC regenerator. The effect
of higher oxygen level on the
selective oxidation of NH3 was
also studied. The data shows
that increasing oxygen levels
from 500 ppmv O2 to 2000 ppmv
O2, over the Pt promoter,
increases the amount of ammo-
nia converted to NOx by about
20%. Both of these observa-
tions are consistent with what is
observed in FCC regenerators
where Pt-based promoters and
high excess O2 levels both tend
to increase NOx emissions.
Resulting Products
CP®
P
Grace Davison’s third generation
low NOx combustion promoter,
CP®
P, has recently been intro-
duced to select refiners for com-
mercial scale evaluation.
Preliminary results from these
trials are confirming that the
intended characteristics of this
third generation low NOx com-
bustion promoter have been
achieved.
CP®
P has been designed as a
platinum free formulation, yield-
ing quick response to afterburn
and/or CO excursion situations,
as traditionally has been
observed with Pt formulated CO
promoters. Yet, CP®
P results in
lower NOx emissions and very
quick NOx emission decay peri-
ods. While “rescue” dosing of Pt
formulated CO promoter would
often result in elevated and lin-
gering NOx emissions for up to
2-4 weeks, the NOx decay peri-
od resulting from “rescue” dosing
of CP®
P tends to span only a
few days. Further, unlike earlier
generations of low NOx promot-
ers, CP®
P often does not
require strict adherence to daily
maintenance dosing. However,
consistent daily dosing of CP®
P
remains the preferred route
towards achieving predictable
afterburn, CO, and NOx emis-
sion control and balance.
Below are the initially received
testimonial responses from
FCCU locations regarding the
performance characteristics of
CP®
P.
Wyoming Refining –
Newcastle, WY
“Wyoming Refining Company
has been a user of Grace
Davison’s CP®
5 combustion
promoter since we started our
FCC up in 2000. We recently
switched to their CP®
P product
and are achieving the same
results as CP®
5. Our reasoning
for the change was to help with
the reduction of NOx in our
regenerator flue gas. So far,
with the addition of CP®
P, we do
not see an increase in the NOx
whenever the Promoter is
added.”
Montana Refining –
Great Falls, MT
"We do see good results and
haven’t seen an increase in CO
with the amounts we have been
using."
The CP®
P usage rate is about
25% lower than the first genera-
tion low NOx promoter. CP®
P is
more active with an immediate
afterburn and CO response, at
similar NOx levels, as with
XNOX®
.
Gulf Coast, USA Refiner
An immediate drop of 40-50°F in
regenerator cyclone tempera-
tures (at constant dense bed
temperatur) was observed after
the switch to CP®
P from a com-
petitive low NOX promoter.
GRACE DAVISON CATALAGRAM 17
The lower temperatures allowed
for a reduction in air rate and
excess O2 in an FCCU that is air
rate limited during warmer
months. Thus providing the flex-
ibility to operate with lower pre-
heat and higher cat-to-oil ratios
during warmer weather. Pre-
viously, operations would
attempt to increase air to oxidize
CO to CO2 in the bed to keep
regenerator dilute phase temper-
ature in check.
Additionally, CP®
P, being a non-
platinum formulated CO promot-
er, greatly enhances the disposi-
tion possibilities of a refiner’s
ecat. CP®
P is competitively
priced to attract FCCU opera-
tions in need of either a low NOx
CO Promoter, or simply a
replacement to an existing mid
activity platinum formulated pro-
moter.
Next Generation Low NOx
Promoter
Grace Davison’s continuing R&D
work on mechanistic pathways
for the formation and destruction
of NOx in the FCC regenerator,
indicate that additional improve-
ments to low NOx promoters are
still possible. Research and field
data show that there is a general
relationship between CO and
NO that makes it difficult to
achieve very low CO levels with-
out dramatically increasing NOx.
By fine-tuning and combining the
properties of an active metal and
the appropriate support material
we have preliminary data that
shows further reductions in NOx,
at constant CO levels, are
achievable. Testing data from
Grace Davison’s RTU, demon-
strate these improvements in
Figures 3A and 3B. The data
reveals that the CO combustion
activity of this fourth generation
promoter is similar to Pt-based
COCombustionActivity(%)
40
50
60
70
80
90
100
0
10
20
30
CP® P 4th Gen LNP
Combustion Promoters
Figure 3a
CO Combustion Activity
NOEmissions(ppmv)
70
75
50
55
60
65
CP® P 4th Gen LNP
Combustion Promoters
Figure 3b
NOx Emission Comparison
18 ISSUE No. 107 / 2010
promoters and CP®
P but makes
lower NOx. We expect this new
technology will be commercial-
ized in 2011.
Summary
Grace research and develop-
ment efforts have led to the
development of CP®
P, a new
low NOx combustion promoter.
Data from multiple field trials has
indicated excellent CO control
with quick response to afterburn
and/or CO excursions, like tradi-
tional Pt-based promoters.
However, unlike traditional pro-
moters, CP®
P provides lower
NOx emissions and very quick
NOx emission decay periods.
This new promoter was devel-
oped as an outgrowth of R&D
work directed towards under-
standing the mechanistic path-
ways for NOx formation in the
FCC regenerator. The reduced
nitrogen species generated dur-
ing the burning of coke in the
regenerator are the key interme-
diate species in minimizing NOx
formation. CP®
P is much more
effective at converting these
reduced species to N2 than Pt-
based promoters, which tend to
convert them to NOx. In addi-
tion, CP®
P is effective at con-
verting NOx that has been
formed in the regenerator back
to N2 via a reaction with reduc-
ing species.
Due to the success of low NOx
promoters and lack of need for
additional infrastructure or other
chemical reactants, these pro-
moters are now considered by
the EPA to be the Best
Demonstrated Technology for
abating NOx emissions from
FCC regenerators. Grace is
continuing work in alignment
with this BDT conclusion by the
EPA, directing continued
research and development
efforts towards further under-
standing both the NOx formation
mechanisms and improved cat-
alytic methods for reducing NOx.
References
1. Frank S. Roser, Mark W. Schnaith, and
Patrick D. Walker, “Integrated View to
Understanding the FCC NOx Puzzle,” UOP
LLC, Des Plaines Illinois, 2004 AIChE Annual
Meeting.
2. Cheng, Wu-Cheng; Habib, E. Thomas,
Jr; Rajagopalan, Kuppuswamy; Roberie,
Terry G.; Wormsbecher, Richard F.; Ziebarth,
Michael S., Fluid Catalytic Cracking,
Handbook of Heterogeneous Catalysis (2nd
Edition) (2008), (6) 2741-2778.
3. New Source Performance Standards
(NSPS) for Petroleum Refineries, at 40
C.F.R. Part 60, Subpart J/Ja. 73 Fed. Reg.
35838 (June 24, 2008). The amendments
were proposed in 2007 as the outcome of
the periodic review of NSPS standards
required under the Clean Air Act -- Section
111(b)(1). 72 Fed. Reg. 27278 (May 14,
2007). The rules provide technical correc-
tions to the existing Subpart J standards and
create a set of new emissions for fluid cat-
alytic cracking units (FCCU), fluid coking
units (FCU), sulfur recovery plants (SRP),
and fuel gas combustion devices for facilities
that were newly constructed, modified or
reconstructed after May 14, 2007. The new
rules became effective on June 24, 2008.
4. Xinjin Zhao, A.W. Peters, G. W.
Weatherbee, Nitrogen Chemistry and NOx
Control in a Fluid catalytic Cracking
Regenerator, Ind. Eng. Chem. Res. 1997, 36,
4535-4542.
5. K. L. Dishman, P. K. Doolin, L. D.
Tullock, NOx Emissions in Fluid catalytic
Cracking Catalyst Regeneration, Ind. Eng.
Chem. Res. 1998,37, 4631-4636.
6. G. Yaluris,, A. Peters, Additives Acieve
Ultra-Low FCCU Emissions, NPRA Paper
AM-05-21, 2005
7. J. O. Barth, A. Jentys, J. A. Lercher, On
the Nature of Nitrogen Containing
Carbonaceous Deposits on Coked Fluid
Catalytic Cracking Catalysts, Ind. Eng.
Chem. Res. 2004,43, 2368-2375.
8. A.W. Peters, J.A. Rudesill, G.D.
Weatherbee, E.F. Rakeiwicz, M.J. Barbato-
Grauso, US Patent 6,143,167 2000, to
W.R.Grace & Co.-Conn.
9. A.W. Peters, E.F. Rakeiwicz, G.D.
Weatherbee, X. Zhao, US Patent 6,165,933
2000.
10. G. Yaluris, and J.A. Rudesill, US Patent
6,881,390, 2005.
11. Oleg S. Alexeev, Sundaram
Krishnamoorthy, Cody Jensen, Michael S.
Ziebarth, George Yaluris, Terry G. Roberie,
Michael D. Amiridis , In Situ FTIR
Characterization of the Adsorption of CO and
its Reaction with NO on Pd-Based FCC Low
NOx Combustion Promoters. Catalysis
Today, Volume 127, Issues 1-4, 30
September 2007, Pages 189-198.
12. Oleg S. Alexeev, Sundaram
Krishnamoorthy, Michael S. Ziebarth, George
Yaluris, Terry G. Roberie, Michael D.
Amiridis, Characterization of Pd-Based FCC
CO/NOx Control Additives by In Situ FTIR
and Extended X-ray Absorption Fine
Structure Spectroscopies. Catalysis Today,
Volume 127, Issues 1-4, 30 September 2007,
Pages 176-188.
13. G. Yaluris, X. Zhao, and A. W. Peters, “
FCCU Regenerator Lab-Scale Simulator for
testing New Catalytic Additives for Reduction
of Emissions from The FCC Regenerator”,
Proceedings of the 212th ACS National
Meeting, Orlando, FL, Aug, 1999, 41 (3)
P.901.
14. Michael Amiridis, Oleg Alexeev, Behnam
Bahrami (Chemical Engineering, University
of South Carolina), Udayshankar Singh,
Michael Ziebarth (W.R. Grace & Co.-Conn.),
Manuscript preparation currently in progress.
GRACE DAVISON CATALAGRAM 19
20 ISSUE No. 107 / 2010
Our newest CO Promoter, CP®
P delivers quick
CO/afterburn response, equivalent to traditional
Platinum formulated promoters with up to 20%
lower NOx emissions compared to competitive
products.
Commercialized in late 2009, six FCC units are
currently using CP®
P and three additional trials are
planned. In commercial applications, CP®
P has
• 75% lower usage rates compared to first
generation low NOx promoter
• Allowed operation at lower excess O2 in an
air-limited FCCU
• An immediate 40 – 50°F drop in hottest cyclone
temperature at constant dense bed temperature
after switch from competitor
Its copper-free formulation allows for enhanced
disposition possibilities for equilibrium catalyst and
has no special handling requirements. CP®
P is
available in
• 5 lb. bags
• 30 lb. pails
• 300 lb. drums
• 2000 lb. totes
Current
Users
Date CP® P
Started
Base
Promoter
Expected
Start 2nd
Qtr 2010
Competitor 1
Non-Pt Based
Promoter
CP® A
Expected
Start 1st
Qtr 2010
XNOX®
CP® 5
Expected
Start 1st
Qtr 2010
Feb ’10
Competitor 1
Non-Pt Based
Promoter
Feb ’10
CP® 5Feb ’10
Competitor 2
Non-Pt Based
Promoter
XNOX®
CP® 5
Jan ’10
Nov ‘09
Sep ‘091
2
3
4
5
6
7
8
9
Table I
Current and Planned CP®
P Users
Grace Davison Introduces CP®
P,
Our Third Generation Non-Platinum
Low NOx CO Promoter
COIndexPercent
1st Generation Low NOx
Combustion Promoter
CP® P
55
50
45
40
35
30
Reduced Variability with CP® P
Figure 1
CP®
P Reduces Variability
catalysts@grace.com www.e-catalysts.comartinfo@grace.com
Catalagram®, Grace®, Grace Davison®, GENESIS®, MIDAS®, IMPACT®, GSR®, AURORA®, ADVANTA®, Super DESOX®, D-PriSM®,
SuRCA®, GSR®-5, OlefinsMax®, OlefinsUltra® and SmART Catalyst System® are registered trademarks in the United States and/or
other countries, of W. R. Grace & Co.-Conn.
ApART™, AT™, DX™ and StART™, SmART Catalyst System® are trademarks of Advanced Refining Technologies, LLC.
ART® and ADVANCED REFINING TECHNOLOGIES® are trademarks, registered in the United States and/or other countries,
of Advanced Refining Technologies, LLC.
Astera™ and Alcyon™ are trademarks of W. R. Grace & Co.-Conn.
Grace Davison® is a business unit of W. R. Grace & Co.-Conn.
This trademark list has been compiled using available published information as of the publication date of this brochure and may not
accurately reflect current trademark ownership.
© 2010 W. R. Grace & Co.-Conn.
The information presented herein is derived from our testing and experience. It is offered, free of charge, for your consideration,investigation and
verification. Since operating conditions vary significantly, and since they are not under our control, we disclaim any and all warranties on the results
which might be obtained from the use of our products. You should make no assumption that all safety or environmental protection measures are
indicated or that other measures may not be required.

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Development of Next Generation Low NOx Combustion Promoters Technical Article _Catalagram 107 Excerpt

  • 1. Catalagram® A Refining Technologies Publication Issue No. 107 / 2010 / www.grace.com In this issue • GENESIS® Catalyst Commercial Update • Distillate Pool Maximization by Additional Hydroprocessing • Salt Deposition in FCC Gas Concentration Units • CP® P - Third Generation Low NOx CO Promoter
  • 2. Dear Refiners, The current refining atmosphere in North American and Europe is the most difficult in over a quarter century. Declining utilization rates, narrow light-heavy differentials, and weak demand for transportation fuels has meant steeply declining profitability for refiners. As the leading supplier of FCC catalysts and additives, Grace Davison is dedicated to helping you navigate this turbulence. Our investment in world-class research and development to constantly invent new products and fine- tune existing ones continues strong in this challenging environment. With our flexible technology base and broad manufacturing capabilities, we deliver the catalyst solu- tions you need to be profitable and the value you deserve. This issue of the Catalagram® highlights the successful application flexibility of our GENESIS® solutions to our customers' challenge of the need to react quickly to changing supply/demand dynamics. These catalysts have been custom blended in 80 applications for over 50 refineries worldwide. As product slate demand changes, GENESIS® catalyst in the unit can be reformulated to maximize profitability and capture short term economic opportunities. To speed implementation, formulation adjustment can take place in the fresh hopper, minimizing the delay often associated with a catalyst change out. We also introduce our third generation non-platinum low NOx CO promoter, CP® P. Our newest CO promoter delivers quick CO/afterburn response, equivalent to traditional platinum formulated promoters, and up to 20% lower NOx emissions compared to competitive products. On the immediate horizon, we introduce our new products AsteraTM and AlcyonTM . Units that are circulation limit- ed can’t take full advantage of improved feed quality. When the FCC catalyst is not active enough regenerator temperatures become too low and desired reactor temperatures can’t be achieved. Some refiners resort to burning torch oil or recycling slurry to provide additional delta coke which is often detrimental to the operation. With its novel, unconventional silica-alumina binder, AsteraTM FCC catalyst not only delivers excellent value but will improve your yield slate and reliability. Best of all, AsteraTM will lower your daily catalyst cost. AlyconTM is a revolutionary new FCC catalyst designed for the maximum activity needed to process hydrotreated feeds. Look for more information from us in the coming months. Our responsibility to our refining customers is the core of our business. We pledge to continue developing the products and services that will maximize your profitability in all economic climates. Joanne Deady Vice President, Global Marketing Grace Davison Refining Technologies A MESSAGE FROM THE EDITOR... GRACE DAVISON CATALAGRAM 1 Managing Editor Joanne Deady and Technical Editor Rosann Schiller
  • 3. 04 Grace Davison’s GENESIS® Catalyst Systems Provide Refiners the Flexibility to Capture Economic Opportunities By Rosann K. Schiller GENESIS® is one of Grace Davison’s most successful catalysts, with 20% of the world’s FCC capacity, having utilized the technology. GENESIS® systems offer refiners formulation flexibility and the ability to realize the desired yield shifts quickly in order to capture dynamic economic opportunities. 13 Development of Next Generation Low NOx Combustion Promoters Based on New Mechanistic Insights By Eric Griesinger, Mike Ziebarth and Uday Singh Grace research and development efforts have led to the develop- ment of CP® P, a new low NOx combustion promoter. Data from multiple field trials has indicated excellent CO control with quick response to afterburn and/or CO excursions, like traditional Pt- based promoters. However, unlike traditional promoters, CP® P pro- vides lower NOx emissions and very quick NOx emission decay periods. 22 Distillate Pool Maximization by Additional LCO Hydroprocessing By Brian Watkins, David Krenzke and Charles Olsen Advanced Refining Technologies® has developed catalysts specifi- cally designed to handle more difficult feeds exemplified by the SmART Catalyst System® technology for ULSD. This technology has been widely accepted, with over 75 units in commercial service since its inception. ART continues to improve its line of ultra high activity ULSD catalysts with the addition of an SRO catalyst. 34 Salt Deposition in FCC Gas Concentration Units By Michel Melin, Gordon McElhiney and Colin Baillie Various operational problems can arise when salt deposition occurs in FCC gas concentration units. Grace Davison Technical Service troubleshoots users of alumina sol catalysts to manage and solve any issues of ammonium chloride deposition. IN THIS ISSUE Catalagram 107 ISSUE No. 107 / 2010 Managing Editor: Joanne Deady Technical Editor: Rosann Schiller Contributors: Colin Baillie Eric Griesinger David Krenzke Gordon McElhiney Michel Melin Charles Olsen Rosann Schiller Uday Singh Brian Watkins Mike Ziebarth Please address your comments to: betsy.mettee@grace.com Grace Davison Refining Technologies Advanced Refining Technologies 7500 Grace Drive Columbia, MD 21044 410.531.4000 www.e-catalysts.com www.grace.com www.artcatalysts.com © 2010 W. R. Grace & Co.-Conn. Catalagram® A Refining Technologies Publication Issue No. 107 / 2010 / www.grace.com In this issue • GENESIS® Catalyst Commercial Update • Distillate Pool Maximization by Additional Hydroprocessing • Salt Deposition in FCC Gas Concentration Units • CP® P - Third Generation Low NOx CO Promoter
  • 4. GRACE DAVISON CATALAGRAM 13 Eric Griesinger Product Manager Environmental Additives Grace Davison Refining Technologies Columbia, MD Mike Ziebarth Manager Synthesis Research Grace Davison Refining Technologies Columbia, MD Udayshankar G. Singh Research & Development Engineer Grace Davison Refining Technologies Columbia, MD The use of low NOx combustion promoters in FCC units has increased in recent years due to stricter NOx emission limits and implementation of EPA consent decrees. Further, the recent EPA issued final amendments to its New Source Performance Standards for Petroleum Refineries indicate that additives are now included as Best Demonstrated Technology in the reduction of FCCU NOx emis- sions. Studies to determine mechanisms by which low NOx promoters reduce NOx, as well as determining the FCCU operat- ing parameters that effect NOx formation are the focus of this paper. A lab scale regenerator test unit was used to study the combustion of coked ecat at con- ditions that closely simulate the regenerator of an FCCU. This unit was used to explore the impact of certain regenerator variables, including excess O2 level and type of combustion pro- moter on CO and NOx emis- sions. In addition, fixed bed reactor experiments were carried out to study the oxidation of reduced nitrogen species on plat- inum (Pt) and non-Pt based com- bustion promoters to help elucidate mechanistic differences. Development of Next Generation Low NOx Combustion Promoters Based on New Mechanistic Insights
  • 5. 14 ISSUE No. 107 / 2010 Based on this improved mecha- nistic understanding of how low NOx combustion promoters work, a new combustion promoter has been developed. Commercial field trials show excellent results. Background FCC units account for about 10% of the nitrogen oxide emis- sions generated by stationary sources in the United States. These NOx emissions are the result of nitrogen impurities in the feed depositing on the cata- lyst during the cracking reaction. When the coke is burned off in the regenerator, a portion of the nitrogen is converted into NOx. Since NOx emissions are a con- tributor to acid rain, precursors in the formation of ground level ozone, and contribute to respirato- ry health impacts, the EPA and various state and local agencies have been tightening NOx emis- sion standards over the last decade1,2. A variety of NOx reduction options, both catalytic and hard- ware oriented, are available to refiners to comply with limits on NOx content emitted from the FCCU regenerator flue gas stream. One of the best meth- ods of meeting these regulations is the use of low NOx combus- tion promoters. This method has the advantage of being simple and inexpensive since it replaces traditional Pt-based promoter, and also typically requires no additional infrastruc- ture or chemical reactants. In addition, the U.S. Environmental Protection Agency concluded that newly adopted emission limits utilizing additives and combustion controls were achievable, cost effective and had fewer secondary impacts than more costly hardware ori- ented control technologies3. The U. S. EPA issued final amendments to its New Source Performance Standards for Petroleum Refineries (NSPS)3 on June 24, 2008. Within this amendment, the EPA states that the currently Best Demonstrated Technology (BDT) to NOx emis- sion control now includes the use of additives in conjunction with an upwardly revised NOx emission limit of 80 ppmv based on a 7-day rolling average. Typically, under EPA Consent Decree proceedings, FCCU operations have been restricted to a NOx emission limit of 20 ppmv based on a 365-day rolling average and 40 ppmv based on a 7-day rolling average. This NSPS amendment now also rec- ognizes the secondary environ- mental impact that many of the hardware solutions inflict upon the environment, inherent in their operation to achieve a 20 ppmv maximum NOx emission limit. These secondary impacts include PM (Particulate Matter) as well as additional SO2 and NOx emissions resulting from increased electrical demand. In addition, many of the hardware solutions require supplementary chemical reactants that add haz- ards and emission problems of their own1. As such, non-plat- inum formulated oxidation pro- moters and advanced oxidation controls typically are anticipated to provide the least overall envi- ronmental impact, as they gen- erally do not generate further secondary environmental emis- sions. Even though there are many advantages for the use of low NOx promoters, there are some limitations, especially with first generation promoters. These include variable and at times lim- ited NOx reduction and also occasionally low CO combustion activity. The variability is thought to be due to the wide range of unit FCCU operating conditions, as well as the variety of regener- ator configurations. The pur- pose of this paper and the R&D work at Grace is to understand the reactions behind NOx forma- tion and destruction so improved additives can be developed that are more effective and less vari- able in their performance. In addition, work is on-going to understand the operating condi- tions that affect NOx formation in order to develop recommenda- tions to help refiners optimize their unit to minimize NOx. NOx Emission Mechanism NOx in the FCC regenerator originates from feed nitrogen being deposited on the catalyst as coke. When the nitrogen containing coke is burned off in the regenerator, about 10% of the nitrogen is emitted as NOx and the remainder is emitted as nitrogen. Thermal NOx, which results from the oxidation of molecular nitrogen (N2), is not a significant source of NOx at FCC regenerator temperatures. This has been shown to be the case both by thermodynamic calcula- tions and experimentally by per- forming a nitrogen mass balance around an FCC pilot plant unit4,5. During the combustion of coke, data indicates that the nitrogen in the coke is first released as N2 or as a reduced nitrogen com- pound, such as HCN. In the presence of water vapor, gener- ated by the combustion of coke, the HCN is hydrolyzed to NH36,7. These reduced nitrogen species are then further oxidized to
  • 6. GRACE DAVISON CATALAGRAM 15 Coke Nitrogen Reduced Nitrogen Species (NH3, HCN) NOx + Reductant Nitrogen (2B) (2A) (1) Figure 1 Major NOx Reduction Pathways either N2 or NOx. The NOx is almost exclusively in the form of NO. Once the NOx is formed it can also react with various reductants, such as carbon or CO to form nitrogen. In full burn units, traditional Pt- based combustion promoters are very effective at reducing CO but also dramatically increase NOx emissions. Low NOx combus- tion promoters were introduced to solve this problem by retain- ing the CO oxidation function but eliminating the sharp increase in NOx. The low NOx combustion promoters typically contain non- Pt noble metals, potentially other transition metals, and have mod- ified alumina supports that help with the NOx reduction func- tion8,9,10. Based on the reaction pathway illustrated in Figure 1 for the for- mation and destruction of NOx, there are two major pathways by which low NOx combustion pro- moters can lower NOx. The first (1) is catalyzing the reduction of
  • 7. NOx to nitrogen. The second (2) is acting on the NOx precursor and minimizing its conversion to NOx. This would be accom- plished by promoting the oxida- tion of the reduced nitrogen species to nitrogen (eqn. 2A) rather than to NOx (eqn. 2B). Equation 2A 4NH3 + 3O2 = 2N2 + 6H2O Equation 2B 4NH3 + 5O2 = 4NO + 6H2O The first mechanism (1) has been shown to be facilitated by Grace combustion promoters. This work is outlined in two papers Grace published jointly with researchers at the University of South Carolina11,12. The data indicated that additives promoted the reduction of NO by CO through an isocyanate inter- mediate stabilized by the surface of the low NOx combustion pro- moter. The second mechanism (2), involving the oxidation of reduced nitrogen species to NOx, is the subject of work in this paper. The research eluci- dating these mechanisms and the development of new Grace low NOx combustion promoters was carried out in a fluidized bed Regenerator Test Unit as well as in a fixed bed reactor, as described below. Experimental Regenerator Test Unit A laboratory scale Regenerator Test Unit (RTU) was utilized to test the performance of low NOx combustion promoters and con- ditions that affect NOx emissions in the FCC regenerator13. The RTU simulates an FCC regener- ator by feeding coked catalyst onto the top of a fluidized bed where the coke is burned off under controlled conditions. Catalyst is also constantly removed, generating an equili- brated catalyst ranging from completely coked to completely regenerated catalyst in the reac- tor. This closely replicates an actual FCC regenerator environ- ment where additive perform- ance can be determined and where regenerator conditions can be systematically changed to determine their effect on NOx emissions. The additives were tested after a metals-free Cyclic Propylene Steam (CPS) deactivation. The commercial FCC catalyst used in the study was steam deactivated for 4 hours at 1500ºF in 100% steam. After deactivation, it was coked in Davison Circular Riser pilot plant using an FCC feed that contained 0.18 wt.% total nitrogen, 0.42 wt.% sulfur, and 5.1 wt.% Conradson carbon. The coked catalyst contained approximately 1 wt.% coke. For testing purposes, the deactivat- ed additive was blended with the coked catalyst at a 0.2 wt.% level. During testing the reactor temperature was maintained at 700ºC, and the excess oxygen was controlled at 1.1%. Data were collected for 60 to 90 min after the steady state was achieved. Fixed Bed Reactor Fixed bed reactor work was car- ried out, in collaboration with University of South Carolina14, to compare the oxidation of the reduced nitrogen species over a variety of noble metals on a low NOx combustion promoter base support. Ammonia was used as the model compound due to its availability, relatively low toxicity and belief that it is a major inter- mediate species in the formation of NOx. The metals were deposited on the support using soluble metal salts and impreg- nating to incipient wetness. The catalysts were dried and then calcined. The oxidation of ammonia in the presence of oxy- gen was carried out at 700ºC to simulate a typical FCC regenera- tor temperature. For each experiment 0.2 grams of additive was blended with 3 grams of quartz in the fixed bed. Prior to analysis, the samples were treat- ed in a 10% O2/He flow at 700ºC. The ammonia feed gas concentration used for the reac- tion was 500 ppm. The testing was carried out using oxygen levels of 500 ppm and 2000 ppm. The data were collected under steady-state conditions at constant gas hourly space veloc- ity (GHSV) of 30 L/gm/hr. The reaction products from the reac- tor were fed to a GC-mass spec- trometer for identification and quantification. Results The oxidation of ammonia to NOx and N2 was carried out over the low NOx combustion promoter support as well as for each of the supported metals. The low NOx combustion pro- moter support was considered the base line and additional con- version considered due to the effect of the metal. The data in Figure 2, for the 2000 ppm O2 case shows that the Pt-based promoter converts a significantly higher percentage of ammonia into NOx than either noble metal #1 or #2. The noble metal #1 catalyst is the most selective for converting NH3 to N2 followed by noble metal #2 catalyst. These results indicate that the selectivi- 16 ISSUE No. 107 / 2010
  • 8. 40 50 60 70 0 10 20 30 Pt Metal #2 Metal #1 Noble Metals NOxFormation(%) Figure 2 NOx Formation vs. Noble Metal Type ty of the combustion promoter in catalyzing the oxidation of reduced nitrogen species to either N2 or NO is a key differ- ence between the performance of Pt and non-Pt promoters in the FCC regenerator. The effect of higher oxygen level on the selective oxidation of NH3 was also studied. The data shows that increasing oxygen levels from 500 ppmv O2 to 2000 ppmv O2, over the Pt promoter, increases the amount of ammo- nia converted to NOx by about 20%. Both of these observa- tions are consistent with what is observed in FCC regenerators where Pt-based promoters and high excess O2 levels both tend to increase NOx emissions. Resulting Products CP® P Grace Davison’s third generation low NOx combustion promoter, CP® P, has recently been intro- duced to select refiners for com- mercial scale evaluation. Preliminary results from these trials are confirming that the intended characteristics of this third generation low NOx com- bustion promoter have been achieved. CP® P has been designed as a platinum free formulation, yield- ing quick response to afterburn and/or CO excursion situations, as traditionally has been observed with Pt formulated CO promoters. Yet, CP® P results in lower NOx emissions and very quick NOx emission decay peri- ods. While “rescue” dosing of Pt formulated CO promoter would often result in elevated and lin- gering NOx emissions for up to 2-4 weeks, the NOx decay peri- od resulting from “rescue” dosing of CP® P tends to span only a few days. Further, unlike earlier generations of low NOx promot- ers, CP® P often does not require strict adherence to daily maintenance dosing. However, consistent daily dosing of CP® P remains the preferred route towards achieving predictable afterburn, CO, and NOx emis- sion control and balance. Below are the initially received testimonial responses from FCCU locations regarding the performance characteristics of CP® P. Wyoming Refining – Newcastle, WY “Wyoming Refining Company has been a user of Grace Davison’s CP® 5 combustion promoter since we started our FCC up in 2000. We recently switched to their CP® P product and are achieving the same results as CP® 5. Our reasoning for the change was to help with the reduction of NOx in our regenerator flue gas. So far, with the addition of CP® P, we do not see an increase in the NOx whenever the Promoter is added.” Montana Refining – Great Falls, MT "We do see good results and haven’t seen an increase in CO with the amounts we have been using." The CP® P usage rate is about 25% lower than the first genera- tion low NOx promoter. CP® P is more active with an immediate afterburn and CO response, at similar NOx levels, as with XNOX® . Gulf Coast, USA Refiner An immediate drop of 40-50°F in regenerator cyclone tempera- tures (at constant dense bed temperatur) was observed after the switch to CP® P from a com- petitive low NOX promoter. GRACE DAVISON CATALAGRAM 17
  • 9. The lower temperatures allowed for a reduction in air rate and excess O2 in an FCCU that is air rate limited during warmer months. Thus providing the flex- ibility to operate with lower pre- heat and higher cat-to-oil ratios during warmer weather. Pre- viously, operations would attempt to increase air to oxidize CO to CO2 in the bed to keep regenerator dilute phase temper- ature in check. Additionally, CP® P, being a non- platinum formulated CO promot- er, greatly enhances the disposi- tion possibilities of a refiner’s ecat. CP® P is competitively priced to attract FCCU opera- tions in need of either a low NOx CO Promoter, or simply a replacement to an existing mid activity platinum formulated pro- moter. Next Generation Low NOx Promoter Grace Davison’s continuing R&D work on mechanistic pathways for the formation and destruction of NOx in the FCC regenerator, indicate that additional improve- ments to low NOx promoters are still possible. Research and field data show that there is a general relationship between CO and NO that makes it difficult to achieve very low CO levels with- out dramatically increasing NOx. By fine-tuning and combining the properties of an active metal and the appropriate support material we have preliminary data that shows further reductions in NOx, at constant CO levels, are achievable. Testing data from Grace Davison’s RTU, demon- strate these improvements in Figures 3A and 3B. The data reveals that the CO combustion activity of this fourth generation promoter is similar to Pt-based COCombustionActivity(%) 40 50 60 70 80 90 100 0 10 20 30 CP® P 4th Gen LNP Combustion Promoters Figure 3a CO Combustion Activity NOEmissions(ppmv) 70 75 50 55 60 65 CP® P 4th Gen LNP Combustion Promoters Figure 3b NOx Emission Comparison 18 ISSUE No. 107 / 2010
  • 10. promoters and CP® P but makes lower NOx. We expect this new technology will be commercial- ized in 2011. Summary Grace research and develop- ment efforts have led to the development of CP® P, a new low NOx combustion promoter. Data from multiple field trials has indicated excellent CO control with quick response to afterburn and/or CO excursions, like tradi- tional Pt-based promoters. However, unlike traditional pro- moters, CP® P provides lower NOx emissions and very quick NOx emission decay periods. This new promoter was devel- oped as an outgrowth of R&D work directed towards under- standing the mechanistic path- ways for NOx formation in the FCC regenerator. The reduced nitrogen species generated dur- ing the burning of coke in the regenerator are the key interme- diate species in minimizing NOx formation. CP® P is much more effective at converting these reduced species to N2 than Pt- based promoters, which tend to convert them to NOx. In addi- tion, CP® P is effective at con- verting NOx that has been formed in the regenerator back to N2 via a reaction with reduc- ing species. Due to the success of low NOx promoters and lack of need for additional infrastructure or other chemical reactants, these pro- moters are now considered by the EPA to be the Best Demonstrated Technology for abating NOx emissions from FCC regenerators. Grace is continuing work in alignment with this BDT conclusion by the EPA, directing continued research and development efforts towards further under- standing both the NOx formation mechanisms and improved cat- alytic methods for reducing NOx. References 1. Frank S. Roser, Mark W. Schnaith, and Patrick D. Walker, “Integrated View to Understanding the FCC NOx Puzzle,” UOP LLC, Des Plaines Illinois, 2004 AIChE Annual Meeting. 2. Cheng, Wu-Cheng; Habib, E. Thomas, Jr; Rajagopalan, Kuppuswamy; Roberie, Terry G.; Wormsbecher, Richard F.; Ziebarth, Michael S., Fluid Catalytic Cracking, Handbook of Heterogeneous Catalysis (2nd Edition) (2008), (6) 2741-2778. 3. New Source Performance Standards (NSPS) for Petroleum Refineries, at 40 C.F.R. Part 60, Subpart J/Ja. 73 Fed. Reg. 35838 (June 24, 2008). The amendments were proposed in 2007 as the outcome of the periodic review of NSPS standards required under the Clean Air Act -- Section 111(b)(1). 72 Fed. Reg. 27278 (May 14, 2007). The rules provide technical correc- tions to the existing Subpart J standards and create a set of new emissions for fluid cat- alytic cracking units (FCCU), fluid coking units (FCU), sulfur recovery plants (SRP), and fuel gas combustion devices for facilities that were newly constructed, modified or reconstructed after May 14, 2007. The new rules became effective on June 24, 2008. 4. Xinjin Zhao, A.W. Peters, G. W. Weatherbee, Nitrogen Chemistry and NOx Control in a Fluid catalytic Cracking Regenerator, Ind. Eng. Chem. Res. 1997, 36, 4535-4542. 5. K. L. Dishman, P. K. Doolin, L. D. Tullock, NOx Emissions in Fluid catalytic Cracking Catalyst Regeneration, Ind. Eng. Chem. Res. 1998,37, 4631-4636. 6. G. Yaluris,, A. Peters, Additives Acieve Ultra-Low FCCU Emissions, NPRA Paper AM-05-21, 2005 7. J. O. Barth, A. Jentys, J. A. Lercher, On the Nature of Nitrogen Containing Carbonaceous Deposits on Coked Fluid Catalytic Cracking Catalysts, Ind. Eng. Chem. Res. 2004,43, 2368-2375. 8. A.W. Peters, J.A. Rudesill, G.D. Weatherbee, E.F. Rakeiwicz, M.J. Barbato- Grauso, US Patent 6,143,167 2000, to W.R.Grace & Co.-Conn. 9. A.W. Peters, E.F. Rakeiwicz, G.D. Weatherbee, X. Zhao, US Patent 6,165,933 2000. 10. G. Yaluris, and J.A. Rudesill, US Patent 6,881,390, 2005. 11. Oleg S. Alexeev, Sundaram Krishnamoorthy, Cody Jensen, Michael S. Ziebarth, George Yaluris, Terry G. Roberie, Michael D. Amiridis , In Situ FTIR Characterization of the Adsorption of CO and its Reaction with NO on Pd-Based FCC Low NOx Combustion Promoters. Catalysis Today, Volume 127, Issues 1-4, 30 September 2007, Pages 189-198. 12. Oleg S. Alexeev, Sundaram Krishnamoorthy, Michael S. Ziebarth, George Yaluris, Terry G. Roberie, Michael D. Amiridis, Characterization of Pd-Based FCC CO/NOx Control Additives by In Situ FTIR and Extended X-ray Absorption Fine Structure Spectroscopies. Catalysis Today, Volume 127, Issues 1-4, 30 September 2007, Pages 176-188. 13. G. Yaluris, X. Zhao, and A. W. Peters, “ FCCU Regenerator Lab-Scale Simulator for testing New Catalytic Additives for Reduction of Emissions from The FCC Regenerator”, Proceedings of the 212th ACS National Meeting, Orlando, FL, Aug, 1999, 41 (3) P.901. 14. Michael Amiridis, Oleg Alexeev, Behnam Bahrami (Chemical Engineering, University of South Carolina), Udayshankar Singh, Michael Ziebarth (W.R. Grace & Co.-Conn.), Manuscript preparation currently in progress. GRACE DAVISON CATALAGRAM 19
  • 11. 20 ISSUE No. 107 / 2010 Our newest CO Promoter, CP® P delivers quick CO/afterburn response, equivalent to traditional Platinum formulated promoters with up to 20% lower NOx emissions compared to competitive products. Commercialized in late 2009, six FCC units are currently using CP® P and three additional trials are planned. In commercial applications, CP® P has • 75% lower usage rates compared to first generation low NOx promoter • Allowed operation at lower excess O2 in an air-limited FCCU • An immediate 40 – 50°F drop in hottest cyclone temperature at constant dense bed temperature after switch from competitor Its copper-free formulation allows for enhanced disposition possibilities for equilibrium catalyst and has no special handling requirements. CP® P is available in • 5 lb. bags • 30 lb. pails • 300 lb. drums • 2000 lb. totes Current Users Date CP® P Started Base Promoter Expected Start 2nd Qtr 2010 Competitor 1 Non-Pt Based Promoter CP® A Expected Start 1st Qtr 2010 XNOX® CP® 5 Expected Start 1st Qtr 2010 Feb ’10 Competitor 1 Non-Pt Based Promoter Feb ’10 CP® 5Feb ’10 Competitor 2 Non-Pt Based Promoter XNOX® CP® 5 Jan ’10 Nov ‘09 Sep ‘091 2 3 4 5 6 7 8 9 Table I Current and Planned CP® P Users Grace Davison Introduces CP® P, Our Third Generation Non-Platinum Low NOx CO Promoter COIndexPercent 1st Generation Low NOx Combustion Promoter CP® P 55 50 45 40 35 30 Reduced Variability with CP® P Figure 1 CP® P Reduces Variability
  • 12. catalysts@grace.com www.e-catalysts.comartinfo@grace.com Catalagram®, Grace®, Grace Davison®, GENESIS®, MIDAS®, IMPACT®, GSR®, AURORA®, ADVANTA®, Super DESOX®, D-PriSM®, SuRCA®, GSR®-5, OlefinsMax®, OlefinsUltra® and SmART Catalyst System® are registered trademarks in the United States and/or other countries, of W. R. Grace & Co.-Conn. ApART™, AT™, DX™ and StART™, SmART Catalyst System® are trademarks of Advanced Refining Technologies, LLC. ART® and ADVANCED REFINING TECHNOLOGIES® are trademarks, registered in the United States and/or other countries, of Advanced Refining Technologies, LLC. Astera™ and Alcyon™ are trademarks of W. R. Grace & Co.-Conn. Grace Davison® is a business unit of W. R. Grace & Co.-Conn. This trademark list has been compiled using available published information as of the publication date of this brochure and may not accurately reflect current trademark ownership. © 2010 W. R. Grace & Co.-Conn. The information presented herein is derived from our testing and experience. It is offered, free of charge, for your consideration,investigation and verification. Since operating conditions vary significantly, and since they are not under our control, we disclaim any and all warranties on the results which might be obtained from the use of our products. You should make no assumption that all safety or environmental protection measures are indicated or that other measures may not be required.