John Murphy, president of Catalyst Group Resources, a subsidiary of TCG Corporation, said recently that refinery catalyst manufacturers are facing tremendous price competition pressure, especially in mature refining processes such as the FCC. Catalysts have become popular and competitive pressures are increasing. . However, in some oil refining and processing industries, there are still differences in catalysts, and catalyst manufacturers are developing more sophisticated solutions. For example, catalyst manufacturers are developing technologies to help US refiners increase raw material suitability, especially processing heavy feedstocks such as synthetic crude oil from Canadian oil sands. Catalyst manufacturers are also actively developing patented technologies that allow refiners to increase the yield of highly profitable products.
Neumann said that BASF expects that global diesel demand will surpass gasoline demand in the long run. Under this expectation, BASF is developing an FCC catalyst that maximizes diesel production. In the United States, petrochemical producers are increasing their ethane cracking capacity, which will lead to a shortage of propylene supply. Therefore, US refiners are looking for solutions to increase the propylene yield of FCC units.
In 2010, BASF announced that the company has begun commercial trials of a new type of FCC catalyst technology that can allow the FCC to achieve a graded response, which is a completely new concept in the field of FCC catalysts. This technology, named Multistage Reaction Catalyst (MSRC) platform, can be combined with BASF's existing FCC technology to achieve the function of having two or more FCC catalysts in a single catalyst particle. This method of fractional reaction can be applied to an FCC unit to achieve the processing of heavy feedstocks or maximize the yield of specialty products.
Cooper said that at the same time, users of hydrotreating catalysts are also looking for more active catalysts to meet the needs of refiners to reduce costs. Topsoe continues to study increasing the dispersion of active metals on the catalyst carrier while maintaining a high degree of dispersion during operation. Because the increase in the activity of the hydrofinishing catalyst means an increase in the amount of processing and an extension of the operating cycle, this can increase profits for the customer.
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