Commercialization of GO-ULTRA: Optimization of Kinetic Model and Review of FCCU Trials

摘要

In 2009, Albemarle introduced a new line of FCC catalysts for gas oil units, called GOULTRArn? (1). Compared to conventional gas oil catalysts, GO-ULTRA offers superiorrngasoline and coke selectivities, and excellent bottoms conversion. These improvementsrnoffer refiners new options to adjust their product slate in response to changes inrntransportation fuel markets.rnThis paper consists of two parts. Part 1 starts with a description of GO-ULTRA, and thenrnfollows the development of a lumped kinetic model, capable of accurately quantifying thernimpressive selectivity improvements over a wide range of conversions. Part 2 presentsrnthe current state of commercialization of GO-ULTRA.rnPart 1. In our first paper on GO-ULTRA (ref. 1), we presented the impressive yieldrnimprovements. A correlation was shown to exist between ACE yield vectors and twornimportant catalyst design elements: 1) an enhanced pore size distribution, and 2) speciallyrnmodified active sites. A kinetic model was used at that time to explain the correlationrnqualitatively, in terms of higher diffusion rates of cracked molecules, and improvedrnactive site selectivities. According to this model, the result was a major reduction inrnovercracking, excessive hydrogen transfer, and coke polymerization.rnRecently, a powerful procedure for fitting ACE data to the aforementioned kinetic modelrnwas developed. In addition, a special extended dataset was measured, with thernconversion range broadened to aid in model fitting. As will be shown, the fit is veryrngood, and the results– a set of cracking rate constants - are completely consistent with thernqualitative rankings previously reported. These constants have many beneficial uses.rnHigh on the list is generation of the catalyst factors needed in Albemarle’s heat balancedrnFCCU models - models that are essential to the process of commercialization.rnPart 2. The second half of this paper reports on the commercialization of GO-ULTRA.rnAcceptance in the refining industry is growing at a rapid pace. GO-ULTRA is alreadyrnbeing used in four units, and many more are on the way. So far, GO-ULTRA is provingrnvery successful in meeting the objectives of the refineries using it. To illustrate thisrnsuccess, one of the ongoing commercial trials is examined in detail: yields, operations,rnand supporting ecat data.