(105a) Joint Ebullated Bed Catalyst Development Program Results in over 30% Reduction in Catalyst Usage

Joint Ebullated Bed Catalyst Improvement Program Results in over 30% Reduction in Catalyst Usage.

Craig McKnight, Ph.D. (Syncrude Canada Ltd.) Wayne Schiewe (Syncrude Canada Ltd.) Josiane M. Ginestra*, Ph.D. (Shell Global Solutions) Wessel Ijlstra (Criterion Catalysts & Technologies, Inc.) Dorian Rauschning (Criterion Catalysts & Technologies, Inc.) David E. Sherwood, Jr., Ph.D. (Criterion Catalysts & Technologies, L.P.) *Presenters

Bitumen upgraders, as well as other refiners, go through a process of continuous change. Continuous change often requires the refiner to reconsider his operation and implement new solutions. Having the available technology to keep pace with continuous change is critical for the continuity of profitable operation.

When a refiner such as Syncrude has an open and long-term relationship with a major technology provider such as Criterion, the results can be fruitful for both sides. A good understanding of the site integration, early insight into new requirements, and continuous input and feedback from the refiner enables the technology provider to focus its catalyst development programs such that dedicated solutions can be made in a timely manner.

Syncrude and Criterion have been working together since 1992 under an Alliance arrangement, and have improved the performance of many of the units at the Syncrude Ft McMurray Upgrader. One example is the joint research and development program to improve the performance of the Syncrude Ebullated Bed (?EB?) bitumen upgrader. Syncrude provides expertise in both commercial operations (Ft McMurray) and Ebullated Bed pilot plant operations (Edmonton). Criterion provides expertise in developing dedicated EB catalyst systems. This continuous program has resulted in a series of unique, new generation EB catalysts, which has allowed the processing of heavier feedstocks while minimizing EB catalyst consumption.

EB hydroprocessing is a commercially proven and reliable technology to upgrade bitumen from oil sands (or other heavy oil streams) to high quality synthetic crude. The online catalyst replacement applied in this technology allows for long cycle lengths under severe conditions. However, high catalyst usage in these types of units, and the resulting high volumes of spent catalyst for disposal, contribute significantly to the overall (variable) cost of the operation.

The most recent Syncrude/Criterion EB catalyst, commercially trialed in 2004, shows significantly improved catalytic stability. Compared to the base catalyst in use at the onset of the development program, catalyst consumption has been reduced in the commercial unit by more than 30% (or almost 2 million lbs/yr) in 2005/2006. The catalyst development work and pilot plant evaluations, which led to this commercial success, will be presented, along with an overview of the recent performance of the Syncrude EB bitumen upgrader.