FCC catalyst technologies expand limits of process capability

This paper reports that over the past 30 or so years, many improvements in fluid catalytic cracking (FCC) operation have been achieved as the result of innovations in catalyst formulation. During the 1990s, new environmental regulations on issues such as reformulated gasoline will place new demands on both the refining industry and catalyst suppliers. An overview of cracking catalyst technology therefore seems in order. Today, high-technology innovations by catalyst manufacturers are rapid, but profit margins are slim. Catalyst formulations are shrouded in secrecy and probably depend almost as much on art as on science. Special formulations for specific cracking applications get the greatest emphasis today. To illustrate this point, OGJ's Worldwide Catalyst Report lists over 200 FCC catalyst designations. Catalysts containing components to enhance gasoline octane now account for about 70% of total U.S. FCC catalyst usage