The FCC process vaporizes and breaks the long-chain molecules of the high-boiling hydrocarbon
liquids into much shorter molecules by contacting the feedstock, at high temperature and
moderate pressure, with a fluidized powdered catalyst.
Hydroprocessing faces significant challenges as crude feeds get heavier; there will be more sulphur
and nitrogen to extract; more aromatics to saturate; more metals to remove; and more coke to
deal with. Refiners have ageing facilities, which may not be designed and optimized to meet new
challenges. As more capital investment is needed, costs for refining fossil fuels will rise,
stimulating markets for renewable energy, making them more competitive with fossil fuels.
The cost of hydrocracking catalysts varies because of composition differences. The catalysts can
be alumina with base metals or contain added crystalline zeolites. High quality ultra-stable type Y
molecular sieve zeolites are used in this service. Nickel-moly or nickel-tungsten are the active
metals frequently used.
FCC additives are used with catalysts to meet specific unit objectives. Higher gasoline octane,
lower gasoline sulfur, lower sulfur oxides (SOx) and nitrogen oxides emissions, lower carbon
monoxide levels, improve fluidization, make more propylene and/or liquefied petroleum gas (LPG)
and improve bottoms cracking are FCC objectives.
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According to Susan Eustis, principal author of the study, “Fluid Catalytic Cracking (FCC) petroleum
refining products overcome limiting factors affecting refinery capacity and operating flexibility to
deliver value and performance. Catalysts are a crucial component in the processing of highly
valued petrochemicals, gasoline, diesel and other fuels.”
The market for refinery catalysts in the oil refining sector at $4,967 million in 2016 is expected to
be worth $6,490 million by 2023, growing at 3.8% on average between 2017 and 2023. There are
500 FCC units being operated globally, each of which requires a constant supply of FCC catalysts.
There are 3,000 HPC units being operated globally, or a capacity of approximately 44 million
barrels per day, each of which typically requires replacement HPC catalysts once every one to four
years.
Companies Profiled
Market Leaders
• Albemarle
• BASF
• Haldor Topsoe
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