Introduction

For decades, refiners have pursued operational synergies between VGO Hydrotreating (FCC-PT) and Fluid Catalytic Cracking (FCC) units. With the tightening of Ultra Low Sulfur Diesel (ULSD) and Gasoline (ULSG) specifications, this pursuit now extends to post-treatment units converting Light Cycle Oil (LCO) and FCC gasoline into compliant products.

Ketjen stands apart as a technology partner with deep expertise across all three domains—FCC, hydrotreating, and post-treatment. Our advanced catalyst portfolio and process modeling capabilities allow us to collaborate closely with refiners to unlock performance synergies and maximize economic returns.

This article presents a case study from a U.S. refinery operating an FCC-PT unit, FCCU, and a selective FCC gasoline hydrotreating unit (GHT). By treating these units as a unified system, Ketjen identified significant opportunities for optimization and value creation.

Background

As the incumbent catalyst supplier for the refinery’s FCCU and GHT units, Ketjen was invited to bid on the VGO HT catalyst for the FCC-PT unit, which had long used a competitor’s NiMo system. Leveraging our unique position, Ketjen conducted a comprehensive technical and economic evaluation of the FCC-PT/FCC/GHT complex.

This initiative exemplifies Ketjen’s ability to integrate its core competencies—catalyst innovation and process expertise—to deliver tailored solutions that challenge the status quo and drive profitability.

Performance Analysis and Optimization Strategy

The refinery’s RFQ targeted 2000 wppm sulfur in the FCC-PT product and a 5-year cycle length. Ketjen’s cross-functional team proposed a more aggressive strategy: using a CoMo or NiCoMo catalyst system with higher HDS activity to reduce product sulfur to 1000 ppm while maintaining the desired cycle length.

This reduction in sulfur would:

• Lower GHT feed sulfur, minimizing octane loss.
• Extend GHT cycle life.
• Generate additional sulfur credits.

However, this approach would increase FCC feed nitrogen from 900 to 1500 wppm—a tradeoff requiring careful FCC catalyst and operating adjustments.

Economic Impact

Based on Ketjen’s proprietary data, reducing FCC-PT product sulfur from 2000 to 1000 wppm would cut GHT octane loss by ~30%, translating to a $54 million benefit over five years.

Ketjen modeled multiple FCC scenarios to assess conversion, product selectivity, catalyst addition rates, and economic outcomes. The recommended STAX™ KF 780 STARS®/KF 907 catalyst system delivered up to 70% higher net economic value per year compared to the base case.

Conclusions

This case study underscores the value of a unified approach to FCC and hydrotreating operations. By treating the FCC-PT, FCCU, and GHT units as an integrated system, Ketjen helped the refinery unlock substantial commercial benefits.

Success requires:

• A catalyst partner with broad technical capabilities and modeling expertise.
• A customer willing to challenge legacy paradigms.
• Open, trust-based collaboration.

Ketjen’s ability to deliver tailored, high-impact solutions across the refining value chain positions us as a strategic ally in driving operational excellence and profitability.

By Andrew Hoffmann, Chantall Reynaud-Dulic, Chuck Novak & Rachel Crouch