Ketjen Corporation has launched SaFeGuard, a new catalyst technology designed to address iron (Fe) poisoning in fluid catalytic cracking (FCC) units.

In a recent 30-day full commercial trial, SaFeGuard demonstrated a 77 per cent improvement in accessibility with a 50 per cent inventory replacement enabling an increase in unit activity, improved bottoms cracking, and ability to process heavy iron-rich feedstocks.

Further testing and predictive modeling suggest that a full 100 per cent inventory changeout could yield up to a 130 per cent increase in accessibility delivering additional improvement in performance.

SaFeGuard delivers a step change in the contaminant Fe and calcium (Ca) tolerance window by minimising the Eutectic formation, thereby keeping catalyst pores open.

This enables higher activity levels and furthers bottoms cracking, ultimately uplifting profit margins.

"We’ve developed a powerful, safe and sustainable solution that addresses iron poisoning and will increase profitability for our customers by allowing for lower-cost feeds and more efficient operations," said Henri Tausch, Ketjen Chief Commercial Officer. "This new technology is the culmination of decades of research aimed at developing industry leading iron and calcium tolerant catalysis and illustrates our commitment to developing innovative solutions that support the evolving needs of our customers."

"SaFeGuard is a great option for refiners who are taking advantage of opportunity crudes and even bio feeds because it is just as effective in combating additional contaminants including nickel, vanadium, calcium, sodium, and silicon," said David Leach, Vice President and General Manager, FCC at Ketjen. "It can be used to process iron-rich feedstocks including heavy, resid, tight oil and renewable feeds, and it’s also great for units facing accessibility limitations because it requires less frequent catalyst replacement."