Eurecat Brochure Web - Catalyst Regeneration Catalyst .

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the world’s leading supplierof environmentally friendlycatalyst services

TOTSUCAT SULFIDING AND PASSIVATIONPatented encapsulation technology completelyseals each TOTSUCAT activated catalyst particle.TOTSUCAT with EZload is delivered in supersacks/big bags with handling and loading the reactor in air.THE EASY TOTSUCAT SOLUTIONDiscover more about EZload at ezload.eurecat.comTotsucat G for Naphthas Totsucat TG for Tail Gas Totsucat SG for SyngasOperational Conditions: Totsucat G, TG, andSG have no sulfur requirement for the feed.Start-up can be in liquid phase or gas phase.Gas recirculation is not required since thecatalyst is totally preactivated. Unit temperaturerestrictions are not an issue.Handling and Loading Conditions:Preactivated catalysts are packaged in drums orflowbins. Standard form is non-passivated andmust be loaded under inert conditions.Passivation allows for loading under air.Type of Start-Up:Load & Go Totsucat E for Cat Feed HT, Diesel HT (Use Totsucat D for ULSD Catalysts)When to use Totsucat E Preactivation: Wherethere is sufficient sulfur in the feed and thedesire to minimize start-up time and avoid theproblems associated with in-situ sulfiding.Typical Applications: Cat Feed, Low Sulfur Diesel,and VGO hydrotreaters.Operational Conditions: Totsucat E requiressufficient sulfur in the feed (at least 0.5 wt%)to complete activation. Start-up can be liquidphase or gas phase. Gas recirculation andsufficient unit temperature (600-620 F) tofinalize activation of the catalyst is required.Handling and Loading Conditions:Preactivated catalysts are packaged in drums orflow-bins. Without passivation, the catalyst mustbe loaded under inert conditions. Optionalpassivation allows for handling and loadingunder air.Totsucat N for Hydrocracker Pretreat CatalystsWhen to use Totsucat N Preactivation:Totsucat N is designed for sulfidingHydrocracker Pretreat (HCPT) catalysts.Preactivated catalyst are especially usefulfor gas phase start-ups. Typical Applications:Hydrocracker Pre-treat catalysts.Operational Conditions: Totsucat N has nosulfur requirement for the feed. Start-up can bein liquid phase or gas phase. Gas recirculation isnot required since the catalyst is preactivated.Unit temperature restrictions are not an issue.Handling and Loading Conditions:Preactivated catalysts are packaged in drumsor flow-bins. Without passivation, the catalystmust be loaded under inert conditions. Optionalpassivation allows for safe handling and loadingunder air.Type of Start-Up:Load & Go TOTSUCAT SULFIDING AND PASSIVATIONWhen to use Totsucat G, TG, and SGPreactivation: For units that are difficult tostart up due to operational restrictions, unitswhere optimum sulfiding cannot be achieved,and/or units where minimal start up time iseconomically beneficial. Typical Applications:NHT, Gasoline Post-treat, Tail Gas, Lube,Hydrogen PlantHDS, and Sour Gas Shift units.

Totsucat CFP for Any HT Unit Starting with Cracked FeedsWhen to use Totsucat CFP Preactivation:Where there are benefits to starting up withcracked feed stocks. Totsucat CFP allows thegradual introduction of cracked feeds duringstart-up without the 3-4 day delay typicallyrecommended by catalyst manufacturers. TypicalApplications: Coker Naphtha or units processingLCO or coker gas oil.Handling and Loading Conditions: Preactivatedcatalysts are packaged in drums or flow-bins.Without passivation, the catalyst must be loadedunder inert conditions. Optional passivationallows for handling and loading under air.Type of Start-Up:Load & Go Operational Conditions: Totsucat CFP has nosulfur requirement for the feed. Start-up can be inliquid phase or gas phase. Gas recirculation is notrequired since the catalyst is completely activated.Unit temperature restrictions are not an issue.Start Cracked FeedsFrom Day 1Totsucat HC for Hydrocracking CatalystsHandling and Loading Conditions: Preactivatedcatalysts are packaged in drums or flow-bins.Without passivation, the catalyst must be loadedunder inert conditions. Optional passivationallows for safe handling and loading under air.Operational Conditions: Totsucat HC has nosulfur requirement for the feed. Start-up can bein liquid phase or gas phase. Gas recirculation isnot required since the catalyst is preactivated.Unit temperature restrictions are not an issue.Type of Start-Up:Load & Go Totsucat D for ULSD CatalystsWhen to use Totsucat D Preactivation:Totsucat D is optimized for sulfiding the latestgeneration of high activity catalysts typicallyused in ULSD applications. Typical Applications:ULSD hydrotreaters.Handling and Loading Conditions: Preactivatedcatalysts are packaged in drums or flow-bins.Without passivation, the catalyst must be loadedunder inert conditions. Optional passivationallows for safe handling and loading under air.Operational Conditions: Totsucat D has nosulfur requirement for the feed. Start-up can be inliquid phase or gas phase. Gas recirculation is notrequired since the catalyst is completely activated.Unit temperature restrictions are not an issue.Totsucat Passivation Type of Start-Up:Load & Go Air Loading of Totsucat Totsucat Passivation : Allows for loading of Totsucat sulfided and activated catalysts under air.Eliminates inert loading requirement for standard Totsucat Passivation for air loading available forNiMo, CoMo, NiCoMo, NiW and Ni catalysts Totsucat CFP with optional Passivation for loadingunder air EURECAT offers on-site loading and start-up assistance.TOTSUCAT SULFIDING AND PASSIVATIONWhen to use Totsucat HC Preactivation:Totsucat HC uses special conditions to carefullysulfide Hydrocracking catalysts. Preactivatedcatalyst are especially useful for gas phase startups. Typical Applications: Hydrocracking Catalysts.

START UP HYDROCRACKERSWITHOUT AMMONIA INJECTIONAVOID AMMONIA AND SULFUR INJECTIONDURING HYDROCRACKER Start-upsTOur newest offering, Totsucat HC-AP,combines the patented Totsucat Activation and Sulfiding process with aspecial “acid protection” step, which usesnitrogen to passivate the acidic sites. WithTotsucat HC-AP, the catalyst will besulfided and the acidic cracking sites willCATALYST SERVICESbe protected from hyperactivity that canlead to exotherms. By treating yourcatalysts with Totsucat HC-AP priorto loading, complicated and timeconsuming sulfiding steps are no longerrequired, and the dangers of ammoniainjection can be totally avoided.In a previous start-up of theirhydrocracker, a Midwest refinerexperienced difficulties injecting theproper amount of ammonia into theunit that was needed to passivate thecracking bed. For their 2012 start-up,this refiner selected Totsucat HC-APtreatment for their hydrocracking catalystand combined that with Totsucat N tosulfide and activate their hydrocrackingpretreat catalyst. The Totsucat treatmentenabled the unit to reach normal SORtemperatures within 36 hours of oil inwithout any exotherms.TOTSUCAT PREACTIVATION: Allows thefastest and safest start-up possible.CATALYST RESALE: Why buy freshcatalysts when regenerated catalystswith “like-fresh” activity are available?SPECIALTY REGENERATION ANDREJUVENATION: Get 95% activity fromSpecial Regeneration and/orRejuvenation. Our techniques aredifferent than a simple carbon burn.ACTIVITY TESTING: Don’t just rely onsurface area and poison levels. With twomulti-tube test units, EURECAT now runs82 activity tests per month to measure thetrue catalyst activity at ULSD conditions.SAS SERVICE: Only get the “good stuff”back with our Sample, Analyze, andSegregate Service.PRESSURE DROP TESTING: EURECAT offersPressure Drop Testing at our laboratories inthe US and Europe. This provides you withreal-world ΔP predictions.TOTSUCAT HC-APemperature excursions are always arisk when starting up a hydrocrackingunit loaded with fresh catalyst. Tominimize the risk, ammonia is ofteninjected during the sulfiding process.The addition of extra nitrogen from theammonia passivates the hydrocrackingcatalyst, reducing the risk of exothermsas the cracking catalyst reaches operatingtemperature levels. However, ammoniaaddition exposes operations personnelto a potentially hazardous material andslows the start-up process. EURECAT hasdeveloped a method to eliminate theneed for ammonia injection.

Ammonia injection was not required, allowingthe refiner to start up their hydrocracker withouthandling any potentially hazardous chemicals.HYDROCRACKERSIn these days of high cracking margins, theperformance of hydrocracking catalysts is criticalto the profitability of the entire refinery, makingit crucial that these specialized catalysts aretreated with the greatest of care. Processing»» Load-and-Go reactor start-ups. The activemetal sulfides are totally formed during theTotsucat treatment. No additional sulfidingagents or complex activation procedures arerequired after loading.»» No temperature excursions»» No need for additional hydrogen at start-up»» Minimal sour water formation during start-up»» No odors or HSE issues related to thehandling of sulfiding chemicals and H2S.START UP WITH CRACKED FEEDSEURECAT has also developed an exclusiveprocedure to gently moderate the initialcatalyst hyper-activity of freshly sulfidedcatalyst. This unique process, called Totsucat CFP, allows the direct introduction of cracked orheavy feeds without the 3-4 day delay typicallyrecommended by catalyst manufacturers.Many CFP users have also experienced lowerdeactivation rates by treating their catalyst withCracked Feed Protection.»» Negligible amounts of H2S are releasedduring reactor heat up, protecting sulfur»» Sensitive units downstream and preventinga sulfur overload of your SRU.»» Starting up with Totsucat -treated catalystsis similar to a restart after an emergency shutdown. Start-up time is reduced to a few hourswhile the risk of damaging the catalyst priorto activation is eliminated. The catalyst loadwill achieve peak performance since sulfidingand activation is controlled at very preciseconditions by the patented Totsucat process.TOTSUCAT HC-APPre-Activating hydrotreating catalysts withTotsucat offers many benefits to the refinerincluding:with Totsucat HC ensures that hydrocrackingcatalysts function as designed without theneed to spend valuable production time onin-situ sulfiding. Totsucat N is designed tomaximize the hydrodenitrification (HDN)activity of the newest NiMo catalysts typicallyused in the pretreat section of the hydrocracker.

WILL YOUR REGENERATED CATALYSTBE A THOROUGHBRED AGAIN?The EURECAT R&D Group has a vast amount of experiencewith activity testing on hydro-treating catalysts.Our first pilot plant MDSU was installed in 1996 and was usedextensively to determine the HDS activity of regenerated catalystsas part of our pool management services.As HDS activity testing became essentialto EURECAT‘s customers, our testingcapacity had to again be expanded tocope with the demand. Our response wasthe installation of a Multi-Tube test Unit(MTU) which allows testing of 10 samplesin 10 parallel reactors of 10 ml each.The MTU runs a three condition protocoland has proven to be extremely reliable.Based on this success, a second MTU wasinstalled in 2010, increasing EURECAT’stotal number of test reactors to 22.HORSE TRADINGIf you don’t have a requirement to reuseyour catalyst within your own refinery,having it activity-tested by EURECAT willopen the door to selling it to an affiliatedrefinery or to a third party.EURECAT’s catalyst purchase and resalenetwork is shared between our affiliatesin the USA, France, Italy, Saudi-Arabia andIndia. Our worldwide sourcing effortsassure a steady supply and demand forregenerated catalysts. In addition, thecatalyst pools we manage for severalcustomers are often in under supply oroversupply of exactly the catalyst thatyou may wish to sell or purchase.Contact EURECAT today for a qualifiedregenerated catalyst and buy a racehorsefor a workhorse price.REGENERATION AND ACTIVITY TESTINGThe introduction of low and ultra-lowsulfur specifications for dieselrequired testing with increasingly deepHDS regimes. Two new MIF units werepurchased in 2003 to carry out testing atthese new conditions. The MIF’s are stillused today, one for HDN activity testingand the other for additional R&D testing.

YOU CAN’T JUDGE A HORSE BY ITS COLOR ANYMOREThe introduction of the latest generation Type II and balanced Type I/Type II catalysts has shaken upthe catalyst regeneration universe. Many of these catalysts require post-treatment after regeneration.Unfortunately, the post-regen activity is less predictable using only the data traditionally gathered in aregeneration study such as surface area and contaminant levels. With today’s advanced rejuvenationtechniques, a critical determining factor for catalytic activity is re-dispersion of the active metals. Truecatalyst performance is best measured with pilot plant activity testing.DON’T JUST ESTIMATE THE ACTIVITY, MEASURE THE ACTIVITYEURECAT can measure both the Hydrodesulfurization (HDS) and Hydrodenitrification (HDN) activity of yourregenerated CoMo or NiMo catalyst in our state of the art pilot plants. Expressed as RVA or RWA versus thefresh reference catalyst, the activity value provides you with a sound decision basis.Our standard MTU test protocol measures catalyst performanceULTRA LOW SULFUR DIESEL HYDROTREATINGat 3 different levels of severity utilizing straight-run gasoil(HDS): The majority of the catalysts we test belong(1.2 wt% S) at the following conditions:to the ULSD category, where the investment andoperational risks associated with regeneration andrejuvenation of the catalyst justify an HDS activity640 / 650 /WABT:LHSV:2 h-1test before the catalyst is reused. Activity testing is660 Fan essential and dependable quality control tool,Pressure:580 psiH2/oil:300allowing the transfer and reuse of your catalystbatch within the corporate catalyst pool. EURECATtracks the activity values for various lots in catalystpools we manage for several major refiners, allowingthe customer to carefully manage when and whereeach lot is applied with minimum risk exposure.EURECAT’s extensive database on activity testingcontains a wealth of process and catalystknowledge. A study (right) carried out by EURECATassessed the effects of different contaminants onthe activity of REACT treated KF-757.HYDROCRACKER / FCC PRETREATMENT (HDN): HDN performance of NiMo catalyst in HC-PT or FCC-PTconditions is tested in a dedicated format on LCO feed at an operating pressure of 1450 psi (100 bar).NON-STANDARD HYDROTREATING TEST FORMATS: EURECAT will gladly develop a customized testingprotocol for your specific process or R&D application. Our MIF testing unit is extremely flexible in terms ofoperating temperature, pressure, LHSV, and H2/oil ratio. Various feed types can also be utilized.HYDROGENATION ACTIVITY / SELECTIVITY TEST: In addition to CoMo and NiMo catalysts, EURECAT can alsotest your Palladium selective hydrogenation catalysts for activity and selectivity, comparing it to the performanceof fresh catalyst. Pilot testing confirms the effectiveness of our exclusive RAISE REACTIVATION treatment.REGENERATION AND ACTIVITY TESTINGACTIVITY TESTING APPLICATIONS

CHERRY PICK THE “GOOD STUFF”WITH EURECAT’S SAS SERVICESAS MAKES SURE YOUR HIGH QUALITYCATALYST IS REUSED AND NOT WASTEDEThe SAS process begins with labeling andnumbering the bins as the spent catalystis unloaded. Accurate records enable thecustomer to determine the position of thecorresponding spent material inside thereactor. Once the entire catalyst load arrivesat EURECAT’s site, samples are sent to ourlab for a complete chemical and physicalanalysis. The lab report is then consolidated intograph illustrating the contaminant profile and asegregation strategy is implemented.For catalyst that is deemed as unregenerable,EURECAT will take care of the metal reclaim orship the unusable portion to a processing site ofyour choice. SAS can also be used to check theefficiency of your metal traps.CATALYST SERVICESTOTSUCAT PREACTIVATION: Allows the fastestand safest start-up possible.SPECIALTY REGENERATION ANDREJUVENATION: Get 95% activity fromSpecial Regeneration and/or Rejuvenation.Our techniques are different than a simplecarbon burn.SAS SERVICE: Only get the “good stuff” back withour Sample, Analyze, and Segregate Service.CATALYST RESALE: Why buy freshcatalysts when regenerated catalysts with“like-fresh” activity are available?ACTIVITY TESTING: Don’t just rely on surfacearea and poison levels. With two multi-tubetest units, EURECAT now runs 82 activitytests per month to measure the true catalystactivity at ULSD conditions.PRESSURE DROP TESTING:EURECAT offers PressureDrop Testing at ourlaboratories in the US andEurope. This provides youwith real-world ΔPpredictions.REGENERATION SAS FOR MAXIMIZING REGEN ACTIVITYURECAT’s exclusive Sample, Analyze, andSegregate (SAS) service is the mostcomprehensive program available forseparating good spent catalyst from the“not-so-good”. With this service, a clearcontamination profile can be developed,enabling the refiner to “cherry pick” thecontainers of catalyst that contain cleanregenerable catalyst. SAS ensures that onlyhigh activity catalyst is regenerated andreturned to the customer, while heavilycontaminated catalyst is quickly sent outfor metals reclamation.

CASE STUDY: SAS FOR A ULSD UNITA complete Sample, Analyze, and Segregate (SAS) service was performed on catalyst from a ULSD reactorsystem with four beds containing a total of 760,000 pounds of CoMo catalyst. The catalyst from the TopBeds of both reactors was vacuumed out, while the Bottom Beds were gravity dumped. All of the bins werenumbered in order as the material was unloaded. This allowed EURECAT to create a contaminant metalsprofile for all of the beds so that the quality of the catalyst from each could be determined.Visual Inspection of 120K lbs CoMoVisual Inspection of 250K lbs CoMoSupportFailFailPassPassRegenerated95% RVAThe analysis showed that about one half of the catalyst in the Lead Reactor Top Bed and all of the Lag Reactor TopBed contained clean catalyst that was suitable for regeneration. Unfortunately, since both Top Beds were vacuumedout, the particle length was much too short for regeneration and therefore all of the material had to be sent formetal reclamation. The Bottom Beds were both successfully rejuvenated, recovering 500K pounds of catalyst withvirtually the same activity as fresh ULSD catalyst. The customer achieved another full cycle with no activity orpressure drop issues after reloading this material.Visual Inspection of 140K lbs CoMoVisual Inspection of 250K lbs CoMoFailFailPassPassSend to ReclaimWHAT IS SASScandinavian Airlines?The Society of Amateur Scientists?Surfers Against Sewage?No, no, and no!SAS is EURECAT’s unique Sample, Analyze, andSegregate service. With SAS, numeroussamples of spent catalyst are carefully analyzedfor contaminant metals, carbon and sulfurcontent, and surface area. From this data, acontamination profile (Fig. 1) can be developed.With this graphical profile, the process ofsegregating the material is straightforward.Regenerated95% RVAOnce the portion of the catalyst you want back isidentified, an activity test can be performed on acomposite sample in our multi-tube pilot unit atULSD conditions. Pilot plant testing guaranteesthat the regenerated catalyst will give you theperformance your units require.Fig. 1— Arsenic, Iron, and Silicon ProfileREGENERATION SAS FOR MAXIMIZING REGEN ACTIVITYSend to Reclaim

EURECAT BED GRADINGGUARDIAN HIGH QUALITY BED GRADING PRODUCTSTRILOBES RINGS INERTSGUARDIAN CR and NR HOLLOW CYLINDERSActive hollow cylinders are available in eitherCoMo (CR) or NiMo (NR) forms offering highvoid space more maximum particulate trappingeffectiveness. Standard GUARDIAN CR and NRcome into 1/8” (3mm), 3/16”(5mm), and 3/8”(9mm) sizes.GUARDIAN CT and NT TRILOBESCost effective active 1/10” (2.5 mm) trilobes areavailable in either CoMo (CT) or NiMo (NT). Theselarge extrudates combine excellent physicalproperties with moderate HDS and HDN activity.1/16” (1.6 mm) and 1/20” (1.3 mm) RESALE CATALYSTSEURECAT’s activity-tested resale catalyst or thirdparty fresh catalyst.CERAMIC INERTSGuardian Inert Ceramic Balls meet the tightestspecifications for structural integrity andconsistent density.GUARDIAN BED GRADING - TOLL MANUFACTURING AND CONDITIONINGT5 PENTA-RINGS and CONVEX BEAMSGuardian T5 and Convex Beams are inertceramics with exceptional physical strength andmaximum void space for reactor topping/holddown and trapping of large particulates.

CUSTOM CATALYST TOLL MANUFACTURINGWith our recent purchase of the Tricat Group, EURECAT is now uniquely qualified to developand manufacture custom catalyst formulations. Our facilities in McAlester, Oklahomainclude laboratories and pilot plants for producing small lots and proof-of-concept samples.We can also develop new custom catalyst formulations to match your application.OUR EXPERTS HAVE HUNDREDSOF YEARS IN THE FIELD OFCATALYST DEVELOPMENTAND PRODUCTION.EURECAT’s custom manufacturing capabilities include the following processes:»» Jet Mill Grinding»» Extrusion»» Drying»» Impregnation»» Reduction»» Calcining»» Milling»» Washing»» Sulfiding»» Mulling»» Screening»» SelectivationALLOW US TO PROVIDE YOU WITH A STRAIGHTFORWARD AND TRANSPARENTCOST ANALYSIS FOR YOUR CUSTOM CATALYST PROJECT ALONGWITH ADVICE ON OPTIONS FOR CONTROLLING YOUR CATALYST COST.GUARDIAN BED GRADING - TOLL MANUFACTURING AND CONDITIONINGEURECAT manufactures and maintains multiple sources of common catalyst intermediates,allowing us to quickly respond to your needs. Eurecat’s facilities in the USA and Europehave controlled atmosphere treatment capabilities such as reduction, selectivation,sulfiding, calcination, and several other catalyst conditioning processes.

EURECAT is the world’s leading supplier of environmentally friendly catalyst services for refineries, gas processingfacilities, petrochemical and chemical plants with a wide variety of environmentally friendly catalyst services:»Catalyst regeneration and rejuvenation, RAISE reactivation»Totsucat sulfiding and activation of catalysts»Catalysts, Regenerated CoMo, NiMo and NiW for resale»Spent Catalyst Acquisition»Spent Catalyst Management»Reactor Management and CARBODUMP EURECAT S.A.ZI Jean Jaurès - 121 av. Marie Curie - B.P. 45 07800 LA VOULTE-SUR-RHONE - FRANCEPhone : 33 (0) 475 620 402Fax : 33 (0) 475 625 518EURECAT FRANCEZI Jean Jaurès - 121 av. Marie Curie - B.P. 45 07800 LA VOULTE-SUR-RHONE - FRANCEPhone : 33 (0) 475 620 402Fax : 33 (0) 475 853 269sales@eurecat.frEURECAT US INC1331 Gemini St., Suite 310Houston - Texas 77058 - USAPhone : 1 281 218 0669Fax : 1 281 218 9850sales@eurecat.comAl-BILAD CATALYST Co - LtdPO Box 10174Jubail Industrial City 31961KINGDOM OF SAUDI ARABIAPhone : 966 (0) 3 358 90 80Fax : 966 (0) 3 358 13 12general@bilad-catalyst.comECORIGEN S.r.l.Contrada Piana del Signore c/o Raffineria di Gela93012 - Gela (CL) - C.P. 61 - Gela Centro - ItalyPhone : 39 (0) 933 846005Fax : 39 (0) 933 846067sales@ecorigen.comPETROVALZAC Parc Econormandie76 430 Saint-Romain-de-Cobosc - FRANCEPhone : 33 (0) 235 310 000Fax : 33 (0) 235 313 535petroval@petroval.comEURECAT DEUTSCHLAND GmbHOT GreppinTricat-Str. (Chemiepark Areal B-Ost)D - 06803 Bitterfeld-WolfenPhone : 49 34 93 75 910Fax : 49 34 93 75 999Eurecat India Catalyst Services Pvt. Ltd.1, Jhagadia GIDCBharuch, Gujarat - IndiaPhone : 91 2643290827info@eurecat.inwww.eurecat.inEURECAT Services Asia Pacific Pte Ltd60 Albert StreetOG Albert Complex #15-12SINGAPORE 189969 - SINGAPOREPhone : 65 9659 3560singapore@eurecat.fr

catalyst hyper-activity of freshly sulfided catalyst. This unique process, called Totsucat CFP, allows the direct introduction of cracked or heavy feeds without the 3-4 day delay typically recommended by catalyst manufacturers. Many CFP users have also experienced lower deactivation rates by treating their catalyst with Cracked Feed Protection.

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forming a spent catalyst. Coke may include adsorbed hydro carbons and true coke, made up of aromatic oligomers.A high temperature regeneration Within a regeneration zone opera tion burns coke from the spent catalyst. Spent catalyst is continually removed from the reaction zone and replaced by essentially coke-free catalyst from the regeneration .

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