ECAT Analysis Guide

~ Davison ECAT ANALYSIS GUIDE
MAT Gas Factor
The Micro Activity Test is a measure of catalyst activity in % wt conversion. The MAT activity is affected by the addition rate of the fresh catalyst, the unit turnover rate, and the metals loading on the equilibrium catalyst, in addition to the fresh catalyst activity and quality.
Gas factor (GF) is the molar hydrogen-tomethane ratio from the MAT test. The gas factor is affected by the contaminant metals level on the equilibrium catalyst, the metals tolerance of the fresh catalyst, and the unit turnover rate.
H2 Yield SCFB Hydrogen yield is the measured hydrogen yield in SCFB from the MAT test. The hydrogen yield is affected by the contaminant metals level on the equilibrium catalyst, the metals tolerance of the fresh catalyst, and the unit turnover rate. The MAT hydrogen yield may not equal the hydrogen yield of the commercial unit, but tracks well with unit value.
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Coke Factor Coke factor (CF) is the ratio of the MAT coke yield (wt%) divided by the kinetic activity, where the kinetic activity = (MAT/100-MAT). Higher coke factor means higher coke per unit of conversion. The coke factor is affected by the contaminant metals level on the equilibrium catalyst, the metals tolerance of the fresh catalyst, and the unit turnover rate.
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Surface Area Surface area (m2/gm) consists of the total of the zeolite and matrix surface areas. Surface area correlates well with activity for similar catalyst types. Changes in surface area reflect changes in severity in the FCC unit from changes in metals levels, addition rates, or unit severity. Z/M Ratio Z/M ratio is a ratio of the zeolite surface area to matrix surface area. The refiner generally balances Z/M ratio of their catalyst to meet unit constraints.
Zeolite Surface Area Zeolite surface area (m2/gm) is the measurement of the small pore surface area associated with the zeolite of the equilibrium catalyst. Zeolite is mainly used to selectively upgrade gas oils to more valuable liquid products.
Matrix Surface Area Matrix surface area (m2/gm) is a measurement of all non-zeolitic surface area in the equilibrium catalyst. Matrix is added to the FCC catalyst to upgrade high boiling range feed to lighter products that are further upgraded by the zeolite.
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Ni ppm Nickel is a contaminant in the FCC feed. Nickel on catalyst causes dehydrogenation reactions which increase hydrogen yield and coke yield in the FCC unit. Nickel has only small effects on catalyst activity. V ppm Vanadium is an FCC feed contaminant. Vanadium deactivates FCC catalyst by destroying zeolite surface area and reducing activity. Vanadium also causes dehydrogenation reactions at 20% to 25% of the equivalent nickel level.
Ni/V Ratio The nickel-to-vanadium ratio is used to identify changes in crude or FCC gas oil sources. It can be used to identify changes in FCC operation.
Na wt% Sodium in the FCC feed deactivates the equilibrium catalyst by destroying zeolite surface area. The rate of activity decline increases as regenerator temperature increases.
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Sb ppm Antimony is a nickel passivator widely used in the FCC industry. In general, antimony can reduce the effects of nickel on coke and hydrogen yield by ~40% when properly applied. Antimony can reduce the effectiveness of some CO Combustion Promoters. Sb/Ni Ratio Antimony is typically added at 0.15 to 0.30 of the level of nickel to achieve optimum passivator performance. Certain more selective catalysts will allow the unit to operate with an Sb/Ni Ratio of 0.15 or less
Sn ppm Tin (ppm) has been used to passivate vanadium in the FCC unit. Limited commercial results have been reported. Tin is not widely used.
Bi ppm Bismuth (ppm) is a nickel passivator when properly applied in the FCC unit.
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Re2O3 wt% Re2O3 is the rare earth exchanged onto zeolite during catalyst manufacture to add activity and control gasoline and olefin production in the FCC. Rare earth limits zeolite dealumination, altering equilibrium catalyst unit cell size. Rare earth per unit of zeolite, not rare earth wt%, is the key. Unit Cell Size, The equilibrium zeolite unit cell size is controlled by the fresh catalyst Si/Al ratio and the rare earth exchange. Catalysts with high unit cell size (>24.30 ) yield high gasoline volume and low olefins. Octane-barrel catalysts have a UCS of 24.27 - 24.30 . Octane and maximum olefin catalysts have a low UCS of <24.24 . Pore Volume cc/g Pore volume is a measure of the void volume in the equilibrium catalyst. Pore volume can be used to determine the type of deactivation occurring in an FCC unit. With hydrothermal deactivation, pore volume remains constant while surface area and activity drop. With thermal deactivation, pore volume, surface area and activity drop.
ABD g/cc ABD is the apparent bulk density of the catalyst. ABD will increase with significant thermal deactivation. ABD will also vary with catalyst type
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Al2O3 wt% Alumina is most useful for tracking the turnover rate to a new catalyst. The alumina content is affected by matrix alumina input, binder level and type, and clay input. Fe wt% Iron is a contaminant in feed and also in the clay of the fresh manufactured catalyst. When added with the feed, iron causes dehydrogenation reactions at ~10% of the equivalent nickel level. Iron can also build on equilibrium catalyst as a result of upstream corrosion.
Cu ppm Copper (Cu, ppm) acts similarly to nickel in causing dehydrogenation reactions in the FCC unit.
TiO2 wt% Titanium is used when tracking the turnover rate to a new catalyst. Titanium is in the clay used in catalyst manufacture.

Pb ppm Lead (Pb, ppm) is present in FCC feeds. Lead is typically sourced from slop streams in the FCC feed. Lead can deactivate the platinum in CO Promoter. CaO ppm Calcium acts to deactivate FCC catalyst. Calcium is found in FCC feeds and refinery slop streams which are fed to the FCC unit.
K2O ppm Potassium acts to sodium deactivate FCC catalyst Potassium is typically sourced from slop streams in the FCC feed.
ZnO ppm Zinc is a contaminant in the FCC feed typically found in lube oil slop streams. Zinc can deactivate the FCC catalyst by blocking pores in the FCC catalyst structure.

Carbon wt% Carbon is measured on the equilibrium catalyst to determine the efficiency of the regeneration. Carbon on regenerated catalyst blocks active sites and reduces the effective activity of the catalyst . Full combustion units typically operate below 0.10 wt% carbon. Partial burn units can operate higher. MAT activity is measured on a carbon free basis. MAT Micro Activity Test (MAT, wt%) is a measure of catalyst activity in %wt conversion. The MAT activity is affected by the addition rate of the fresh catalyst, the unit turnover rate, and the metals loading on the equilibrium catalyst, in addition to the fresh catalyst activity and quality.
CO Index CO Index measures the ability of the FCC catalyst to convert a fixed amount of CO to CO2 in the presence of O2. CO index is used to measure the effectiveness of CO Promoter.

Particle Size 0-40 The 0-40 content aids in circulation of the catalyst. The 0-40 content is also used to determine cyclone efficiency and to identify attrition sources. Particle Size 0-80 The 0-80 content is an indicator of the flow characteristics of the equilibrium catalyst inventory.
APS, The average particle size (APS) is an important indicator of the flow characteristics of the equilibrium catalyst inventory. APS is affected by the fresh APS distribution, catalyst attrition, and cyclone efficiency.
UMB/UMF The Umb/Umf is a fluidization factor used to determine the fluidization capabilities of an equilibrium catalyst. The value of a good Umb/Umf is unit dependent. However, higher Umb/Umf represents an inventory with better flow characteristics.

MAT vs. Vanadium + Sodium This industry comparison plot identifies where the refiner compares to other FCC units. It can be used to identify the range where refiners operate. In general, the higher the vanadium and sodium level, the lower the MAT due to catalyst deactivation. Hydrogen Yield vs Nickel Equivalent Increasing Nickel Equivalent increases hydrogen yield in the FCC unit. This industry comparison plot identifies potential improvements from catalyst changes or effects of increasing metals in the FCC feed.
Coke Factor vs. Nickel Equivalent Increasing Nickel Equivalent increases coke yield in the FCC unit. This industry comparison plot identifies potential improvements from catalyst changes or effects of increasing metals in the FCC feed.
Gas Factor vs. Nickel Equivalent Increasing Nickel Equivalent increases the hydrogen-to-methane ratio in the FCC unit. This industry comparison plot identifies potential improvements from catalyst changes or effects of increasing metals in the FCC feed.

Hydrogen vs. Nickel Equivalent Increasing Nickel Equivalent increases hydrogen yield in the FCC unit. This comparison plots the effect of Nickel Equivalent on hydrogen yield for the different catalysts used in an individual FCC unit. Coke Factor vs Nickel Equivalent Increasing Nickel Equivalent increases coke yield in the FCC unit. This comparison plots the effect of Nickel Equivalent on coke factor for the different catalysts used in an individual FCC unit.
Gas Factor vs. Nickel Equivalent Increasing Nickel Equivalent increases the hydrogen-to-methane ratio in the FCC unit. This comparison plot the effect of Nickel Equivalent on ecat H2/CH4 (gas factor) for the different catalysts used in an individual FCC unit.
Nickel vs. Vanadium Ratio This industry comparison plot identifies the nickel-to-vanadium ratio of all FCC units.

Send Feed and Slurry Samples to: GRACE Davison 7500 Grace Drive Columbia, MD 21044 Tel. (410) 531-4000 Attn: Al Huddleston
Send Equilibrium Catalyst Samples to: W. R. Grace & Co.-Conn Analytical Service Center 5601 Chemical Road Baltimore, MD 21226-1698 Tel. (410) 355-4900

ECAT Analysis Guide

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~ Davison ECAT ANALYSIS GUIDE

MAT Gas Factor

~ Davison ECAT ANALYSIS GUIDE

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~ Davison ECAT ANALYSIS GUIDE

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