basf multi stage reaction catalysts

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Page 1 Multi-Stage Reaction Catalysts: A Breakthrough Innovation in FCC Technology J. B. McLean, B. W. Hoffer, G. M. Smith, D. M. Stockwell, and A. S. Shackleford BASF Corporation, Catalysts Division Introduction BASF’s Multi-Stage Reaction Catalyst (MSRC) platform is a breakthrough in FCC manufacturing. The innovative manufacturing development takes advantage of staged reactions with different catalytic attributes in much the same way that staged hydrotreating catalyst loading permits different reaction zones in a fixed-bed reactor vessel. The concept of staged reactions is not new to the refining industry, but its application to a circulating system such as FCC is a true advancement in catalyst technology. The manufacturing platform can utilize any of the existing catalyst technologies including BASF’s Distributed Matrix Structures (DMS) 1,2 and Proximal Stable Matrix and Zeolite (Prox-SMZ) 3,4 to create the stages. The location of the various stages can be specifically engineered to achieve maximum value for the customer. There are a myriad of possibilities for combining different catalyst technologies in the inner and outer stages depending on the specific objectives such as the processing of heavier feedstocks or to maximise specific product yields. This novel manufacturing process is based on in-situ technology and involves several key sequential manufacturing steps. One of the key success factors in the development of MSRC technology is the binding process, unique to the in-situ manufacturing process, where Y zeolite grows across the boundary between catalyst stages, acting as a binder and giving the catalyst particle excellent attrition resistance properties. The first product utilizing MSRC manufacturing is Fortress™. Fortress is designed for resid feed applications, where contaminant metals passivation is critical. MSRC manufacturing technology was successfully scaled up and demonstrated in 2010 with Fortress, and two refinery trials were initiated. HALO™ the second catalyst offering from BASF under the Multi Stage Reaction Catalyst manufacturing platform will be ready for commercial trials in 3 Q 2011. HALO is engineered to

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  • Page 1

    Multi-Stage Reaction Catalysts:

    A Breakthrough Innovation in FCC Technology

    J. B. McLean, B. W. Hoffer, G. M. Smith, D. M. Stockwell, and A. S. Shackleford

    BASF Corporation, Catalysts Division

    Introduction

    BASFs Multi-Stage Reaction Catalyst (MSRC) platform is a breakthrough in FCC manufacturing.

    The innovative manufacturing development takes advantage of staged reactions with different

    catalytic attributes in much the same way that staged hydrotreating catalyst loading permits

    different reaction zones in a fixed-bed reactor vessel. The concept of staged reactions is not new

    to the refining industry, but its application to a circulating system such as FCC is a true

    advancement in catalyst technology.

    The manufacturing platform can utilize any of the existing catalyst technologies including BASFs

    Distributed Matrix Structures (DMS)1,2 and Proximal Stable Matrix and Zeolite (Prox-SMZ)3,4 to

    create the stages. The location of the various stages can be specifically engineered to achieve

    maximum value for the customer. There are a myriad of possibilities for combining different

    catalyst technologies in the inner and outer stages depending on the specific objectives such as

    the processing of heavier feedstocks or to maximise specific product yields.

    This novel manufacturing process is based on in-situ technology and involves several key

    sequential manufacturing steps. One of the key success factors in the development of MSRC

    technology is the binding process, unique to the in-situ manufacturing process, where Y zeolite

    grows across the boundary between catalyst stages, acting as a binder and giving the catalyst

    particle excellent attrition resistance properties.

    The first product utilizing MSRC manufacturing is Fortress. Fortress is designed for resid feed

    applications, where contaminant metals passivation is critical. MSRC manufacturing technology

    was successfully scaled up and demonstrated in 2010 with Fortress, and two refinery trials were

    initiated.

    HALO the second catalyst offering from BASF under the Multi Stage Reaction Catalyst

    manufacturing platform will be ready for commercial trials in 3 Q 2011. HALO is engineered to

  • Page 2

    provide attrition resistance comparable to Petromax with equivalent yields, coke and bottoms

    selectivity to NaphthaMax III. As with Fortress, a two stage system is used but in this case it

    delivers an outer stage with highly active zeolite. The staged approach allows for a reduction on

    the level of Y zeolite in the particle as well as a reduction in the diffusion path length. The inner

    stage is composed of activity modifying material which also serves as an anchor for the outer

    stage. Due to the reduced level of zeolite in the catalyst particle, there is an additional benefit to

    HALO in the form of a reduction of RE level with no performance deficit.

    MSRC Concept

    The approach of the new BASF Multi-Stage Reaction Catalyst (MSRC) platform is to combine two

    or more existing FCC catalyst functionalities within a single catalyst particle. The location of the

    various stages can be specifically engineered to achieve maximum value for the customer. This

    can be related to processing of heavier feed stocks, or to maximize specific product yields in the

    FCC unit. The MSRC platform can include existing catalyst technologies like DMS (for gasoline

    maximization) or Prox-SMZ (diesel maximization), but is based on a novel and unique

    manufacturing concept.

    The first product from this new platform, Fortress, is designed for resid feed applications, where

    contaminant feed metal passivation is crucial. In particular, traces of nickel in the resid feed have

    a detrimental effect on the catalyst performance. In state of the art resid FCC catalysts like Flex-

    Tec, a specialty alumina is integrated in the catalyst formulation to trap the nickel and form

    nickel aluminate which is less deleterious for dehydrogenation reactions in the FCC riser. By

    examining spent FCC catalysts from refineries with electron microscopy, it was generally

    observed that while vanadium is distributed homogenously through the particles; nickel mainly

    deposits and accumulates on the outer surface of the catalyst, as depicted in Figure 1. It would

    thus be advantageous to concentrate the nickel trapping alumina at the outer layer of the catalyst

    to make it more effective. With current catalyst technology the specialty alumina is uniformly

    distributed through the catalyst microsphere. This makes a large portion of it, located in the

    interior of the particle, unavailable to react with the nickel and is essence wasted.

    BASF has addressed this situation using the MSRC approach. The inner stage of the catalyst has

    the DMS structure to allow enhanced diffusion of heavy molecules and selective pre-cracking on

    the exposed zeolite surface, maximizing gasoline yields (Ref. 1). The outer-stage is also based

    on DMS technology, but is enriched with specialty alumina to trap the nickel directly where it

    enters and deposits on the catalyst as depicted in Figure 2. The technology is analogous to that

  • Page 3

    employed with Flex-Tec (Ref. 2) and Stamina (Ref. 4), but with the improved spatial distribution of

    the trapping alumina offers more efficient material utilization and better performance potential.

    The manufacturing process for this two-stage reaction catalyst is based on BASFs unique DMS

    manufacturing technology and involves multiple consecutive steps (Fig. 3). First a precursor

    microsphere based on proven DMS technology with a reduced particle size is formed. This

    microsphere is then added to a second slurry, which has a Flex-Tec like formulation including

    elevated concentrations of the nickel passivating specialty alumina, and spray-dried again to yield

    a two-stage microsphere with the required final FCC particle size.

    The FCC catalyst is then manufactured by growing zeolite from the kaolin nutrients in the multi-

    stage microsphere. The zeolite grows in both stages and across the interface and will act as a

    binder to hold the stages together, preventing selective attrition of the outer stage. Zeolite growth

    and catalyst activity are in line with current DMS platform products, as are all physical properties.

    These novel MSRC and Ni passivation enhancement concepts result in cost-effective resid FCC

    performance that is a breakthrough innovation and offers rich potential for future MSRC

    applications.

    Development of Fortress

    The basis for the development of the Fortress catalyst was the observation that Ni accumulates

    mainly in the outer 5-10 microns of the equilibrium FCC catalyst (Ref. 5). This is depicted in

    Figure 1. Geometric calculations show that the weight ratios of the two stages for a ~8 micron

    outer stage thickness and a normal FCC particle size distribution are about 1:1. The addition of a

    solid inner-stage particle to the recipe makes the production of MSRC more complex than

    existing FCC catalysts. Scanning electron microscopy of the early samples clearly demonstrates

    the multi-stage configuration of the particles (Fig. 4). By modifying the microsphere formulation,

    the density of inner and outer stage components were optimized in order to allow maximum

    diffusion rates, without impacting the staged configuration. After successful demonstration of

    manufacturing MSRC catalysts on pilot scale and encouraging testing data, the project was

    quickly transferred to commercial manufacturing scale. The plant production trials required the

    capabilities of multiple manufacturing plants to make first the inner stage microspheres, followed

    by the construction of the outer stage material, and finally zeolite crystallization and finishing to

    make the catalyst (see Fig. 2).

  • Page 4

    The particle size distribution of the resulting MSRC microspheres is shown in Fig. 6. The graph

    shows that the inner stage particle has an average particle size (d50) of 64 m and the final

    particle (inner + outer stage) of 80 m, resulting in an average outer stage thickness of 8 m. The

    thickness is fairly constant throughout the particle size distribution. This is important since the

    expected Ni penetration depth would be fairly constant across the entire particle size range, so

    that both larger and smaller particle sizes should have comparable outer stage thickness.

    The attrition resistance of the commercially manufactured catalyst was measured with two

    standard attrition testing techniques: Roller and Airjet (Table I). The table shows that attrition

    properties are very similar to Flex-Tex, indicating that the two stages are very well connected and

    form a mechanically stable particle. Since the zeolite grows between and chemically bonds to the

    DMS matrix support materials in both stages, attrition resistance and other physical properties

    such as density are not any different than existing DMS products such as Flex-Tec. This was

    also validated in the commercial performance, which is described later in this paper.

    Table I. Attrition properties

    Flex-Tec Fortress

    Roller (wt% loss/h) 18 16

    Airjet Rate* (wt% loss/h) 2.7 2.9 * Losses in first hour of operation are disregarded

    The product from the first manufacturing campaign was evaluated in the lab using BASFs ACE

    bench scale testing unit. ACE testing was done with a commercial resid feed at 960F and

    variable cat/oil ratios to generate yield response curves. The performance of Fortress was

    compared to the Flex-Tec catalyst that was being supplied to the target trial refinery FCC unit.

    Prior to ACE testing the samples were deactivated and metallated using BASFs Cyclic

    Metallation and Deactivation Unit (CMDU) with intermediate steaming to target approximately

    2800 ppm Ni and 1100 ppm V, as well as commercially representative equilibrium catalyst activity.

    Table II shows the properties of the pseudo-equilibrium catalysts. As stated earlier, the chemical

    and physical properties of Fortress are very similar to Flex-Tec; the difference is the distribution of

    alumina: concentrated in the outer-stage (Fortress) versus uniform (Flex-Tec).

    It must to be noted that the proper laboratory preparation of a pseudo-equilibrium catalyst for a

    resid cracking performance evaluation is not trivial. This is because conventional (Mitchell) pore

    volume impregnation methods result in Ni distributed uniformly throughout the catalyst microsphere, thus penetrating much further into the microsphere than observed on an FCCUs E-

  • Page 5

    cat. Because H2 production from impregnated metals is a linear process, Fortress and Flex-Tec

    will appear to have the same Ni tolerance by pore volume impregnation. Resid FCC units on the

    other hand will result in Ni deposition mostly on the alumina-enriched outer stage however, so the

    correct answer will be for MSRCs to outperform catalyst technologies employing uniformly

    dispersed active ingredients. This correct answer cannot be obtained by pore volume

    impregnation.

    Table II. Properties of catalysts for ACE testing

    Flex-Tec Fortress

    Fresh

    TSA (m2/g) 300 301

    MSA (m2/g) 72 69

    REO (wt %) 3.1 3.7

    APS (m) 76 76

    0-40 m (wt %) 11 10

    0-80 m (wt %) 54 55

    Deactivated (CMDU)

    Ni (ppm) 2797 2718

    V (ppm) 1133 1050

    Steamed TSA (m2/g) 115 123

    Steamed MSA (m2/g) 36 38

    ZSA/MSA 2.2 2.2

    The ACE results are listed in Table III. Fortress catalyst hydrogen and coke yields were reduced

    with about 15% at similar metal content as Flex-Tec, with a corresponding increase in gasoline

    yield. Clean testing in absence of metals showed no differences in coke and bottoms yields,

    demonstrating that no diffusion limitations occur in lab testing and that the effect observed in

    metals testing is a passivation effect. Since H2 production is a direct measure of metals

    dehydrogenation activity, it is clear that Fortress is achieving improved passivation. This is in line

    with the laboratory prototypes as shown in Figure 5.

  • Page 6

    Table III. Product yields (wt %) at 70% conversion

    Flex-Tec Fortress

    Hydrogen 0.53 0.44

    Total C4- 15.9 15.5

    Gasoline 49.4 50.4

    LCO 20.1 20.1

    HCO 9.9 9.9

    Coke 4.7 4.1

  • Page 7

    Fig. 2. Simplistic representation of alumina distribution in current resid catalyst

    Flex-Tec (left) versus novel MSRC resid catalyst technology (right).

    clay slurry

    H2Odryer

    calciner

    Step 1: Inner stage microsphere

    Alumina free Inner stage MS(~65 m)

    clay slurry

    H2Odryer

    calciner

    Step 1: Inner stage microsphere

    Alumina free Inner stage MS(~65 m)

    clay slurry+ alumina+ Inner stage MS

    H2Odryer

    calciner

    Step 2: Outer stage microsphere

    Two-Stage MS(~80 m)

    clay slurry+ alumina+ Inner stage MS

    H2Odryer

    calciner

    Step 2: Outer stage microsphere

    Two-Stage MS(~80 m)

    Step 3: Zeolite crystallization and after-treatment

    MicrosphereCausticSilicate

    BaseExchange

    Rare-earthExchange Calciner

    Multi-Stage ReactionCatalystNa-Y

    Step 3: Zeolite crystallization and after-treatment

    MicrosphereCausticSilicate

    BaseExchange

    Rare-earthExchange Calciner

    Multi-Stage ReactionCatalystNa-Y

    Fig. 3. Manufacturing sequence of MSRC technology

    Alumina

    Fortress (Resid MSRC) Flex-Tec

  • Page 8

    Fig. 4. SEM pictures of early MSRC lab samples show multi-stage concept

    0.20

    0.25

    0.30

    0.35

    0.40

    0.45

    0.50

    65.0 70.0 75.0 80.0

    Conversion, Wt%

    Wt%

    Hyd

    roge

    n FlexFlex--TecTec

    FortressFortress

    Fig. 5. Hydrogen yield in ACE testing of lab sample of Fortress compared to Flex-

    Tec. The samples were deactivated with CMDU to 3000 ppm Ni and 1000 ppm V

    Core shell catalyst with lower density cores

  • Page 9

    0

    20

    40

    60

    80

    100

    0 30 60 90 120 150

    Inner stage

    + Outer stage

    % finer than

    particle size (micron)

    Fig. 6. Particle size distribution of inner stage and final plant produced

    microspheres

    Commercial Performance of Fortress

    Fortress entered into the first of two commercial trials in the second half of 2010. The trial that is

    furthest along is a short contact time resid unit located in the United States. The unit operates in

    deep partial burn and low reactor severity, with primary constraints of wet gas compressor and air

    blower limited. The refiners economic objects are to maximize residue rates while minimizing

    bottoms yields. With the excellent metals tolerance of Fortress, the expected reduction in

    hydrogen yield can be reduced to alleviate the wet gas compressor limit, and the improvement in

    coke selectivity can allow more operating flexibility within these constraints.

    The unit was using Flex-Tec with together with purchased equilibrium catalyst (ECat) for metals

    flushing. Flex-Tec had replaced a competitive catalyst in early 2010 based on the results of a

    catalyst evaluation. For the cleanest comparison, the purchased ECat was removed prior to the

    start of the trial. As such there are three different periods of operation compared: Flex-Tec with

    Ecat, Flex-Tec without Ecat, and Fortress without Ecat.

    The trial was supported by analysis of the refinerys ECat and fines data. The refinery sent twice

    weekly ECat samples and weekly fines samples. Samples enter the BASFs Refinery Returns

    system and are systematically analyzed for chemical properties, physical properties, activity and

  • Page 10

    selectivities. The activity and selectivities are measured on an Advance Cracking Evaluation

    (ACE) unit. This is a standardized testing method using a fixed fluid bed, which simulates SCT

    (short contact time) riser performance. It runs all the ECats under the same conditions (feed,

    temperature, and cat:oil ratio) providing a good basis for comparison. Below are the typical ECat

    values for before and after the purchased ECat was removed.

    With the removal of purchased ECat, the metals increased due to lower catalyst addition rates.

    Nickel alone increased from ~7,500 ppm to ~9,500 ppm. Despite the increase in metals, the

    hydrogen make off the ACE unit did not increase as showing in Figure 7. Equivalent nickel in

    Figure 7, calculated by Ni + V/4 + Fe/10 + 5 Cu 4/3 Sb, represents the equivalent

    dehydrogenation activity of the metals on the ECat and the antimony passivation effect.

    Transitioning from Flex-Tec without purchased ECat to Fortress without purchased ECat, the

    hydrogen selectivity off the ACE improved by 12%. The cross plot of the data in Figure 8 shows

    how the average hydrogen yield decreased from 0.41 wt% to 0.36 wt% with Fortress,

    demonstrating the improved metals passivation.

    FACT 71 wt%Nickel 7400 ppmVanadium 2600 ppmDelta Iron 0.23 wt%Antimony 2000 ppmLead 100 ppmCarbon on Catalyst 0.2-0.5 wt%Equivalent Nickel 5600 ppm

    With Purchased ECatFACT 71 wt%Nickel 8900 ppmVanadium 2700 ppmDelta Iron 0.30 wt%Antimony 2300 ppmLead 100 ppmCarbon on Catalyst 0.2-0.6 wt%Equivalent Nickel 6800 ppm

    Without Puchased ECat

  • Page 11

    0.2

    0.3

    0.4

    0.5

    0.6

    0.7

    -200 -150 -100 -50 0 50 100Day

    AC

    E H

    2 Yi

    eld

    30003500400045005000550060006500700075008000

    Equi

    vale

    nt N

    icke

    l (pp

    m)

    ACE H2 Yield ECat Equivalent Nickel

    Fortress w ithout Ecat

    Flex-Tec w ithout Ecat

    Flex-Tec w ith Ecat

    Figure 7: Figure ACE Cat lab data during the trial period, ACE hydrogen yield and

    ECat equivalent nickel

    0.20

    0.25

    0.30

    0.35

    0.40

    0.45

    0.50

    0.55

    5000 5500 6000 6500 7000 7500 8000Equivalent Nickel (ppm)

    AC

    E H

    2 Yi

    eld

    (wt%

    )

    Flex-Tec w ith Ecat Flex-Tec w ithout Ecat Fortress w ithout Ecat

    Figure 8 ECat lab data during the trial period, ACE hydrogen yield versus ECat

    equivalent nickel

  • Page 12

    The improved metals tolerance of Fortress can also be seen by the improvement in coke

    selectivity. Figure 9 shows the ACE coke factor (coke yield adjusted for activity) as it

    corresponds to the equivalent nickel. As with the ACE hydrogen yield, the removal of purchased

    ECat did not increase the coke factor despite the increase in equivalent nickel of over 1000 ppm.

    With Fortress, the coke factor has significantly decreased. Comparing the ACE coke yield from

    the transition of Fortress to Flex-Tec (Figure 10), the coke yield decreased by 17%. This

    dramatic decrease in coke of ~0.7 wt% for the same conversion is unexpected. A general rule of

    thumb is a 7:1 ratio of hydrogen reduction to coke reduction. With a hydrogen yield reduction of

    0.05 wt% this corresponds to an expected 0.35 wt% reduction in coke. A reduction in coke of

    ~0.7 wt% is twice what can be explained from the hydrogen reduction, and in a positive direction.

    1.0

    1.3

    1.6

    1.9

    2.2

    2.5

    -200 -150 -100 -50 0 50 100Day

    AC

    E C

    oke

    Fact

    or

    3000

    35004000

    45005000

    5500

    60006500

    70007500

    8000

    Equi

    vale

    nt N

    icke

    l (pp

    m)

    ACE Coke Factor Equivalent Nickel

    Figure 9 ECat Lab Data during the trial period, ACE Coke factor and Equivalent

    nickel

  • Page 13

    2

    2.5

    3

    3.5

    4

    4.5

    5

    5.5

    6

    66 68 70 72 74 76

    ACE Conversion (wt%)

    AC

    E C

    oke

    Yiel

    d (w

    t%)

    Flex-Tec w ith Ecat Flex-Tec w ithout Ecat Fortress w ithout Ecat

    Figure 10 ECat Lab data during the trial period, ACE coke yield versus ACE

    conversion

    Since less mass is being converted into hydrogen and coke, the delta mass is showing up as 0.7

    wt% more LPG + Gasoline Yield (Figure 11). A commercial unit can further realize addition

    benefit from the improved coke selectivity by being able to lower the regenerator temperature

    thus increasing cat:oil ratio or by lowering the CO2/CO ratio resulting in increased liquid yield.

    As expected from the fresh catalyst properties, there were no changes observed in attrition or unit

    losses from the transition from Flex-Tec to Fortress. The particle size distribution of the fines

    from the ESP shows no change across the transition (Figure 12).

  • Page 14

    61.061.562.062.563.063.564.064.565.065.566.0

    67 68 69 70 71 72 73 74ACE Conversion (wt%)

    AC

    E LP

    G +

    Gas

    olin

    e (w

    t%)

    Flex-Tec w ithout Ecat Fortress w ithout Ecat

    Figure 11 ECat Lab data during the trial period, LPG + Gasoline vs. Conversion

    0

    2

    4

    6

    8

    10

    12

    14

    16

    0.1 1 10 100 1000

    Particle Size (microns)

    Frac

    tiona

    l (%

    )

    Day 103 Day 68 Day 40 Day -3 Day -72

    Figure 12 ESP Fines PSD shows no changes

  • Page 15

    A post-audit study of the trial was completed on the ACE unit using the refiners feed and

    mimicking the refiners operating conditions comparing the fully changed out Ecat samples of

    Flex-Tec and Fortress. The ACE comparison shows a decrease in hydrogen of 15%, decreasing

    from 0.65 wt% to 0.55 wt%. The coke yield decreased by 0.5 wt% for the same conversion. This

    is in complete alignment with both expectations and the data already discussed from the routine

    Ecat monitoring. Some of the results are shown in Figure 13.

  • Page 16

    Figure 13: ACE Post-Audit testing using the refinery feed and mimicking the

    refiners operating conditions

    0.40

    0.45

    0.50

    0.55

    0.60

    0.65

    0.70

    0.75

    0.80

    60 65 70 75 80

    Conversion (wt%)

    Hyd

    roge

    n (w

    t%)

    Flex-Tec Fortress

    50

    52

    54

    56

    58

    60

    62

    64

    66

    60 65 70 75 80

    Conversion (wt%)

    LPG

    + G

    asol

    ine

    (wt%

    ) Flex-Tec Fortress

    2.0

    2.2

    2.4

    2.6

    2.8

    3.0

    3.2

    3.4

    3.6

    3.8

    60 65 70 75 80

    Conversion (wt%)

    Dry

    Gas

    (wt%

    )

    Flex-Tec Fortress

    6

    8

    10

    12

    14

    16

    18

    60 65 70 75 80

    Conversion (wt%)

    Bot

    tom

    s (w

    t%)

    Flex-Tec Fortress

    5

    6

    7

    8

    9

    10

    11

    12

    13

    14

    60 65 70 75 80

    Conversion (wt%)

    Cok

    e (w

    t%)

    Flex-Tec Fortress

    6

    8

    10

    12

    14

    16

    18

    6 8 10 12 14

    Coke (wt%)

    Bot

    tom

    s (w

    t%)

    Flex-Tec Fortress

  • Page 17

    There is a second trial of Fortress at another US refinery. The expected benefit of the improved

    nickel passivation in this unit is expected to be slightly less than the prior unit because the nickel

    is less at 3000 ppm. Like the previous refinery, this is a comparison to Flex-Tec and purchased

    ECat was removed from the inventory. The typical ECat properties before and after the removal

    of purchased ECat is shown below. Another feature of this unit is a very high level of

    contaminant iron (~ 1 wt%). At this time the unit is operating well with Fortress but it is too early

    to tell the results of the trial.

    Conclusions

    The MSRC manufacturing concept represents a breakthrough development in FCC catalyst

    technology. Through this novel multi-stage approach to catalyst manufacturing, BASF is able to leverage

    the success of its proven FCC catalyst technologies and enable the development of next generation catalysts

    that address the challenges and objectives of refiners in today's rapidly evolving refining landscape. The

    first product based on BASFs FCC catalyst concept MSRC, Fortress, has been developed and scaled up to

    commercial production and is demonstrating improved performance in metals passivation in early refinery

    trials.

    BASF is currently undergoing manufacturing trials for the second product based on the MSRC

    concept. HALO is engineered with an outer stage of highly stable zeolite resulting in a reduced diffusion

    path length which improves selectivity, delivers high bottoms conversion with low coke, and high gasoline

    and light olefin yields. The reduced diffusion path length achieved through the MSRC manufacturing

    process enables HALO to deliver high performance, consistent with BASFs Distributed Matrix Structures

    (DMS) based products, while exhibiting better attrition characteristics as a result of the high opacity.

    BASF intends to expand the number of Fortress applications, commercially launch HALO, and introduce

    other exciting new technologies based on the MSRC concept.

    FACT 71 wt%Copper 70 ppmNickel 2700 ppmVanadium 2200 ppmDelta Iron 0.9 wt%Antimony 600 ppmLead 200 ppmEquivalent Nickel 3400 ppm

    With Purchased ECatFACT 69 wt%Copper 70 ppmNickel 3500 ppmVanadium 3200 ppmDelta Iron 1.1 wt%Antimony 900 ppmLead 200 ppmEquivalent Nickel 4200 ppm

    Without Puchased ECat

  • Page 18

    References

    1) NaphthaMax - Breakthrough FCC Catalyst Technology for Short Contact Time

    Applications; J. B. McLean and D. M. Stockwell, NPRA AM-01-58

    2) Distributed Matrix Structures a Technology Platform for Advanced FCC Catalytic

    Solutions; J. B. McLean, W. A. Weber, and D. H. Harris, NPRA AM-03-38

    3) The Role of FCC Catalyst Technology in Maximizing Diesel Production, J. B. McLean,

    NPRA AM-09-34

    4) Stamina - New FCC Catalyst for Maximum Distillate Yield Demonstrated in Big Wests

    Salt Lake City Refinery; M. Kraus, N. Kiser, Q. Fu, J. Yang, O. Thornton, and J. Finch,

    NPRA AM-10-171

    5) Kugler, E.L., and Leta, D.P., Journal of Catalysis 109 (1988), 387.

    Authors: Joseph B. McLean BASFGlobal Technology Manager [email protected] With our 35 years of experience, Joe has led the market introduction of BASFs Distributed Matrix Structures (DMS) and Proximal Stable Matrix and Zeolite (Prox-SMZ) platforms. He holds a BSChE from Princeton University, an MSChE from the University of California, and several patents. Alexis S. Shackleford BASFTechnical Support Engineer [email protected] Prior to her work at BASF, Alexis was a Process Engineer working with refinery process units. She holds a BSChE from Michigan State University with a minor in Biochemical Engineering. Alexis currently manages the best-in-class Technical Services program that BASF offers to its refinery clients. David M. Stockwell BASFSenior Research Associate [email protected] David has over 25 years experience with BASF (formerly Engelhard) developing products and solutions specifically for the FCC industry. David was the principal inventor for BASFs ground-breaking Distributed Matrix Structures (DMS) technology platform, which enabled the NaphthaMax product; and most recently the Multi-Stage Reaction Catalyst (MSRC) manufacturing platform. He holds a B.S. degree from the University of Rochester and a M.S., and Ph.D. from the University of Connecticut. David current holds 17 U.S. Patents. Bram W. Hoffer BASFSenior Research Engineer

  • Page 19

    [email protected] Bram has led the Fortress R&D program from lab phase up to commercial trials in the FCC manufacturing plants. He has over 7 years of experience in industrial catalyst development and worked for BASF in Germany, Belgium and USA. Bram holds a PhD and MS in Chemical Engineering from Delft University of Technology, The Netherlands, and holds six US patents. Gary M. Smith BASFResearch Chemist [email protected] Gary is a Research Chemist with 30 years experience in FCC catalyst research and development. In addition to MSRC, he has worked on the development of a number of catalyst technologies, including MOA (Maximum Olefins Additive) and holds 4 patents.