Catalyst and Process Development Services
In order to commercialize a promising catalyst material, the process conditions for its application need to be optimized. We examine a wide range of parameters like temperature, pressure, gas-flow rate, different catalyst aging stages, and different feed-stocks. And, we evaluate them using comprehensive kinetic studies and modeling. Furthermore, at hte we can evaluate startup and shutdown procedures, activation and deactivation behavior, and regeneration processes. Taking knowledge obtained in the lab and scaling up allows our customers to effectively bridge the gap between high throughput catalyst screening and pilot plant scale. We formulate the experimental strategy, the catalytic materials are provided either by our customers or synthesized in our own synthesis laboratories. We deliver testing data and their evaluation, the catalyst and process IP stays with our customers.
Test catalysts and feeds for Fluid Catalytic Cracking (FCC) under relevant process conditions but with laboratory scale budgets
The micro downflow unit (MDU) is based on a lab-scale technology and offers an entrained catalyst flow reactor system analogous to commercial fluid catalyst cracking units (FCCUs). It can be operated within a wide range of process conditions, including elevated pressures which are typical for FCCUs. Furthermore, the MDU is fully automated and cost-efficient as only small amounts of catalysts and feeds are required. Processability of a broad range of feedstocks has been demonstrated, ranging from naphtha and vacuum gas oil to residue feeds and crude oils. It includes the latest software solution myhte™ for integrating, storing, retrieving, analyzing, and visualizing data.
- Entrained flow reactor as commercial FCCU
- Pressures typical for an FCCU or a riser can be adjusted
- Since catalyst and feed move in the direction of gravity back-mixing is low
- Size, required material amounts, and operating expenditures in the range of laboratory methods
- Experiments at catalyst reactor residence times / contact times comparable to riser reactors
- Capability of simulating high severity operations (high cat-to-oil ratio)
- Cost-efficient (operation, catalyst, feedstock)
- Fully automated lab system
- 5 crackings per 8 hour shift w/ optional increase to 18 crackings per day
- Mass balances 98 +/- 2 %
- Reproducible results matching well with circulating riser units and commercial FCCUs
- Flexible and broad parameter range
- Variety of feedstocks possible: VGO, high resid VGO, light cut naphtha, pyrolysis oils, biogenic feeds and full crude oil
- Feedstocks with CRC’s 0-10 % can be processed
Operating pressure: 0.2 - 3.5 barg
Reactor temperature: up to 700 °C
Catalyst inlet temperature: up to 750 °C
Oil pre-heat : up to 250 °C
Oil feed rate: 3 - 12 g/min
Cat-to-oil ratio : 3 - 50
Experiment duration: 1 min (can be adjusted)