Could everyone please share information on the use of catalysts and additives in the FCC catalytic cracking units at your refineries?

Let me explain first: we are a small factory that produces refining catalysts, focusing on the main catalysts and additives used in catalytic cracking FCC processes. Compared to some large state-owned catalyst manufacturers, I believe the quality of the products we produce is no worse than theirs. In short, for a small catalyst manufacturer like ours, product quality is the foundation of survival.

Sinopec has two such facilities, Changling and Qilu Catalyst Plants, both of which use their own systems

I work for CNPC; we use catalysts produced by Lanzhou Refinery

Our factory used Lanlian products in the past, but later switched to Qilu ones, with the model RICC-3. The additives are from other manufacturers.

Lanzhou Petrochemical’s catalyst LDO-70, with the anti-coking agent Z-18 as an additive

I started using the catalyst from Zhilu Zhoucun here, and later used one from Changling.

Industrial Application Report on the Rare Earth Heavy Oil Catalytic Cracking Additive RSA-200Ⅱ Type, Shandong ** Chemical Group Co., Ltd., October 2008. I. Introduction The catalytic cracking unit of Shandong ** Chemical Group Co., Ltd. has an annual processing capacity of 600,000 tons. In previous processing, the average yield of gasoline was 37%, the average yield of diesel was 32%, and the average yield of liquefied gas was 9.6%. Considering market demand as well as our company’s current equipment and production capabilities, adjusting the product mix to increase the production of gasoline and liquefied gas will bring better economic benefits to our company. At the same time, there have been significant changes in the properties of raw materials recently, especially a marked increase in heavy metal content. This has led to a decrease in the liquid yield from the unit, an increase in slurry volume, and a reduction in processing capacity. Therefore, it is essential to use a catalyst that can alter the product distribution, increase the production of gasoline and liquefied gas, possess strong resistance to metal contamination, and exhibit good cracking performance for heavy oil. II. Selection of RSA heavy oil catalytic cracking additive: To reduce the risk associated with catalyst replacement in the plant, we conducted preliminary evaluations on the RSA heavy oil catalytic cracking additive, which is currently used by several local refineries in Shandong. The overall performance is good, and it can be matched with the catalytic cracking catalysts provided by current major catalyst manufacturers. With the properties of the feedstock and operating conditions remaining essentially unchanged, this agent can effectively alter the product distribution, increase the relative yields of liquefied gas and gasoline, while also promoting greater conversion of heavy oil; the yield of light oil increases significantly by more than 1%, and the amount of oil slurry decreases significantly by more than 1%. Therefore, it was decided to use it. III. Properties of RSA-200Ⅱ rare earth heavy oil catalytic cracking additive
Appearance: Flowable microspheres in light yellow or slightly red color. Al2O3 ≥25 (w/w)%; Wear index ≤3.0% (w/w)%; Apparent bulk density: 0.60–0.75 g/mL; Specific surface area ≥300 m2/g; Pore volume ≥0.35 mL/g.
Sieve analysis results: 0–40 μm ≤20 (v/v)%; 0–149 μm ≥85 (v/v)%; A.P.S in the 65–80 μm range. Microreactivity (800/4 h, 100% H2O): ≥80%.

IV. Method of use:
1. First stage: From October 13 to 19, 2008, add a mixture of 1.5 tons of CORH catalyst and 2.5 tons of RSA-200Ⅱ additive per day. The proportion of the RSA--200Ⅱ additive in the total catalyst amount was gradually increased from 0% to 20%. At this point, the proportion of the RSA--200Ⅱ additive is limited, so it hardly shows any effect; in catalytic cracking, it is primarily the CORH catalyst that plays a role. 2. Phase 2: From October 19 to 25, 2008, the mixture of 1.5 tons of CORH catalyst and 2.5 tons of RSA--200Ⅱ additive was continued to be added on a daily basis. Increase the proportion of the RSA--200Ⅱ additive in the total catalyst amount from 20% to 40% gradually. At this point, the effect of the RSA--200Ⅱ additive begins to become apparent; the distribution of the products changes gradually, and the yields of gasoline and liquefied gas increase significantly. V. Calibration Results
1. Main operating conditions of the unit:
Reaction temperature (°C): 530
Regeneration temperature (°C): 690
Reaction pressure (kPa): 160
Regeneration pressure (kPa): 190
Main air flow rate (m³/h): 72,000

2. Yield performance of the unit:

| Stage | Auxiliary agent ratio | Gasoline | Diesel | Liquefied gas | Slurry | Light oil yield | Total yield | Slurry specific gravity | Activity |
|-------|------------------------|----------|--------|---------------|--------|----------------|------------|------------------------|----------|
| Phase 1 | 10.13 | 37.410 | 31.110 | 10.160 | 5.470 | 78.680 | 84.15 | 1.0304 | 30.2 |
| | 10.14 | 38.160 | 31.220 | 9.200 | 5.440 | 78.580 | 84.02 | 1.0334 | 30.7 |
| | 10.15 | 36.250 | 31.070 | 10.100 | 7.030 | 77.420 | 84.45 | 1.03 | 30.7 |
| | 10.16 | 35.940 | 33.060 | 9.530 | 7.290 | 78.530 | 85.82 | 1.0444 | 30.7 |
| | 10.17 | 34.470 | 31.570 | 9.710 | 7.810 | 75.750 | 83.56 | 1.0544 | 30.2 |
| | 10.18 | 38.471 | 30.381 | 9.720 | 5.929 | 78.572 | 84.501 | 1.0598 | 30.2 |
| | 10.19 | 39.018 | 29.273 | 10.212 | 5.571 | 78.503 | 84.074 | 1.0421 | 31 |
| Average | 0%–20% | 37.10 | 31.10 | 9.80 | 6.36 | 78.00 | 84.36 | 1.0421 | 30.5 |

Phase 2:
| Stage | Auxiliary agent ratio | Gasoline | Diesel | Liquefied gas | Slurry | Light oil yield | Total yield | Slurry specific gravity | Activity |
|-------|------------------------|----------|--------|---------------|--------|----------------|------------|------------------------|----------|
| | 10.21 | 40.775 | 27.584 | 11.550 | 4.744 | 79.909 | 84.653 | 1.0497 | 31.9 |
| | 10.22 | 41.554 | 27.559 | 11.618 | 5.674 | 80.731 | 86.405 | 1.0501 | 30.5 |
| | 10.23 | 42.087 | 27.724 | 11.328 | 5.396 | 81.139 | 86.535 | 1.0508 | 30.5 |
| | 10.24 | 41.537 | 27.052 | 10.179 | 6.18 | 78.768 | 84.948 | 1.0461 | 30.2 |
| | 10.25 | 41.248 | 26.464 | 11.189 | 5.501 | 78.901 | 84.402 | 1.0478 | 31.4 |
| | 10.26 | 42.117 | 28.654 | 10.477 | 4.453 | 81.248 | 85.701 | 1.0591 | 30.2 |
| Average | 20%–40% | 41.43 | 27.41 | 10.97 | 5.42 | 79.81 | 85.23 | 1.0506 | 30.8 |

Note: There is an error in the measurement using the radar level gauge for the liquefied gas tank; 10 tons of liquefied gas are added daily starting from the 15th. This data is provided for reference only. 3. Trend chart of gasoline yield: 4. Trend chart of liquefied gas yield: 5. Trend chart of diesel yield: 6. Trend chart of slurry yield: 7. Trend chart of slurry specific gravity: 8. Trend chart of light oil yield: 9. Trend chart of total yield: 10. Trend chart of catalyst activator performance: VI. Explanation of the basis for calculating the calibration results: In accordance with the provisions of the technical agreement, the calibration of a catalyst’s industrial suitability should be carried out using the existing installation, while maintaining basically consistent feedstock and operating conditions. However, it is currently difficult for oil sources at various refineries to remain stable within the specified time periods (the baseline comparison time before additive addition and the evaluation time after addition). **There are significant changes in the oil source before and after adding RSA–200Ⅱ additive to the petrochemical product. Added RSA--200Ⅱ additive starting from October 13, 2008. On October 14, 2008, the levels of Ca, Fe, and Na in the crude oil used for processing increased sharply. The Ca level reached 314 ppm, which is nearly 6 times the Ca content in the oil processed in the previous batch. The Fe level reached 74 ppm, which is nearly twice the Fe content in the oil processed in the previous batch. Na reached 52 ppm, which is nearly 8 times the Na content in the oil processed in the previous batch. Due to changes in the oil source, we can no longer use the average value of the production statistics from the 15 days prior to the use of the RSA-200Ⅱ additive as a baseline for comparison. Given this situation, we will add the RSA-200Ⅱ additive in the initial stage (at this time, the proportion of RSA-200Ⅱ additive in the catalyst amount is very small, with the main component of the catalyst being CORH catalyst). ) as a blank comparison baseline. The production data obtained when the RSA-200Ⅱ additive accounts for more than 20% of the total inventory volume is used as the calibration data, from which the evaluation report is generated. The product distribution table provided by the intensification unit of Shandong **Chemical Group Co., Ltd. is used as the source of data for evaluation. During the evaluation process, Zibo Huaqing Powder Materials Technology Co., Ltd. collected and analyzed samples in accordance with the **urgent requests and the provisions of the technical agreement, as follows: Date, Raw oil, Balancing agent, Waste material: 10.14 – √ √ √; 10.17 – √ √ √; 10.20 – √ √; 10.24 – √ √ √. The analysis results are shown in the table below: Material, Date, Fe, Ce, Na, V, Ni, SA, MA, Units: ppm, ppm, ppm, ppm, ppm, m2/g, %: Raw oil: 9.30 – 40, 53, 7, 84, 24 – –; 10.14 – 74, 314, 52, 34, 15 – –; 10.17 – 44, 56, 17, 14, 13 – –; 10.24 – 12, 32, 11, 9, 4 – –. Balancing agent: 10.14 – 6050, 13015, 3400, 6215, 3850, 86.86, 58; 10.17 – 5890, 16115, 5800, 6250, 3800, 89.25, 60; 10.20 – 6780, 16780, 4900, 6090, 3895, 88.08, 62; 10.24 – 7100, 15810, 5400, 6365, 3955, 89.03, 64. Waste material: 10.14 – 17965, 19630, 2500, 7100, 5170 – –; 10.17 – 20275, 40520, 4300, 6350, 4660 – –; 10.20 – 17320, 30720, 4300, 6625, 4860, 72.46 –; 10.24 – 17075, 28525, 3700, 6420, 4975, 85.92 –. VII. Summary: 1. The addition of the RSA-200Ⅱ additive can alter the product distribution. Starting from the 13th, the distribution of gasoline and diesel began to improve significantly, with the gasoline yield increasing by over 4% ； The diesel yield decreases by 3%–4% ； The LPG yield increased by more than 1.0% (the data can only be used as a reference due to errors in LPG level measurement). Considering our company’s equipment setup and market demands, it can bring us high economic benefits. 2. The addition of the RSA-200Ⅱ additive is beneficial for the conversion of heavy oil. After adding the additive, the liquid level at the bottom of the tower decreased significantly, the amount of reprocessed oil increased, and the specific gravity of diesel became higher. The light oil yield shows an upward trend (an increase of over 1%), the total yield also shows an upward trend (an increase of nearly 1%), the slurry yield shows a downward trend (a decrease of nearly 1%), and the specific gravity of the slurry shows an upward trend (an increase of nearly 0.01). 3. It has a strong ability to resist heavy metal pollution; due to a sudden increase in metallic impurities in the crude oil, the calcium content in the balancing agent reaches 15,000 ppm, iron reaches 6,000 ppm, sodium reaches 5,000 ppm, vanadium reaches 6,000 ppm, and nickel is close to 4,000 ppm. Under such conditions of high metal impurity contamination, the RSA-200Ⅱ additive still maintained the activity of the balance agent in the device, ensuring its smooth operation. 4. The RSA-200Ⅱ additive offers excellent flexibility in use. The amount of RSA-200Ⅱ additive can be adjusted flexibly based on the condition of the crude oil and the activity of the balancing agents in the plant. 5. Zibo Huaqing Powder Materials Technology Co., Ltd. has a strong awareness of after-sales service; during the evaluation process, it sends technicians to the company for free sample analysis once every about 4 days, and maintains active communication with the production staff. We recommend that the company establish a long-term and stable cooperative relationship with Zibo Huaqing Powder Materials Technology Co., Ltd. Shandong ** Chemical Group Co., Ltd. 2008-10-31

I compared the FCC catalytic cracking catalyst production processes at the three major catalyst manufacturing sites in China with those of our small private company, and came to the following conclusions. If you think what I said makes sense, please just reply with a smiley face. 1. Large catalyst manufacturers offer a wide variety of catalyst types, with a comprehensive range; smaller private companies have a limited selection of catalysts and specialize in a particular type. Companies like ours specialize solely in FCC catalytic cracking catalysts. 2. Large catalyst manufacturers have multiple production facilities, each of which is used to manufacture different types of products ； Small private companies usually have only one set of production equipment, dedicated to manufacturing a specific type of product. 3. For a specific type of catalyst, the production processes used by large catalyst manufacturers and small private catalyst manufacturers are the same, or at least essentially the same. In that case, if large catalyst manufacturers can produce high-quality products, then small catalyst manufacturers like ours can also produce products of the same high quality. 4. Large catalyst manufacturers have high production volumes per unit of production equipment; an FCC production unit can produce tens of thousands of tons per year. Smaller catalyst manufacturers, on the other hand, have lower production volumes, with annual outputs of only a few thousand tons. Higher production volumes lead to lower costs, but large-scale equipment does not allow for as precise control over production process parameters as smaller equipment does. As a result, smaller equipment is able to produce products of higher quality compared to those produced by larger equipment. 5. During the catalyst production process, it is necessary to continuously sample and monitor the quality of the product. When quality deviations are detected through sampling and analysis on large-scale equipment, making adjustments takes a long time, and by that time, dozens of tons of defective products may already have been produced. Smaller equipment allows for faster adjustments, and fewer defective products are produced during that time. 6. We’ll talk about this again tomorrow. . . . . . :lol

I can take it. . . . . . . . . . . . . . . . . . . .

Catalytic devices rely on catalysts; making a good choice in this regard can bring significant benefits. The performance of catalysts from abroad is roughly similar to that of those produced domestically, but what really matters is the stability and properties of the raw materials used.