As refining markets continue to shift, operators increasingly need catalyst strategies that offer both adaptability and sustained performance. Ketjen’s collaboration with SK Energy is a strong example of how tailored catalyst design can unlock new value while maintaining the operational reliability refineries depend on.
SK Energy’s #1 RFCC unit in South Korea, historically operated as a max-gasoline unit, found itself in a changing landscape. Post-COVID propylene economics declined, prompting the refinery to significantly reduce ZSM-5 additive usage. While the adjustment made economic sense, it unintentionally impacted FCC naphtha octane and C4 olefin production—two factors critical to maximizing gasoline pool quality and overall profitability. For a refinery known for its disciplined optimization and willingness to trial best-in-class technologies, the challenge became clear: adapt the catalyst approach to meet new market demands without eroding long-standing performance advantages.
Rather than offering a standard product, Ketjen partnered closely with SK’s technical team to develop DENALI™ ACTION™, a catalyst engineered specifically for the unit’s unique operating environment.
Built on Ketjen’s proven DENALI™ platform, the redesigned formulation reflected SK’s objectives, feed characteristics, and unit constraints. The development process was highly collaborative—combining economic modeling, lab testing at SK’s R&D center, technical alignment between both teams, and a thoughtfully structured commercial trial program. This approach underscores Ketjen’s commitment to partnership-driven innovation.
The three-month commercial trial of DENALI ACTION delivered clear, demonstrated benefits. LPG yield increased, with the majority of the uplift coming from valuable olefins. FCC naphtha Research Octane Number improved significantly, supporting gasoline blending needs. Selectivity shifted favorably toward C4 olefins at a time when propylene margins were weak, helping SK capture more value from each barrel. Importantly, these gains came without sacrificing bottoms upgrading, coke selectivity, or iron tolerance—even with heavier feed contaminants. Economic analysis using Singapore benchmarks showed an attractive $0.79/bbl uplift, achieved through catalyst optimization alone.
The success carries particular weight in the Asia-Pacific region, where refinery configurations and feed profiles vary widely. In this complex environment, DENALI ACTION proved its versatility on heavy, residue-rich feeds—not just the lighter paraffinic streams typically associated with ACTION technologies. Following the trial, SK adopted a flexible blend of DENALI and DENALI ACTION catalysts, allowing the refinery to dynamically adjust ratios as market conditions evolve.
The SK Energy partnership demonstrates the impact of deep technical engagement and customized catalyst design. By aligning unit needs with market realities, Ketjen delivered a solution that enhances profitability while preserving operational integrity and reinforcing its commitment to innovation tailored to each customer’s unique challenges.