Impact of catalyst and feed properties on the fouling and deactivation of naphtha hydrotreater catalysts

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About 1 million barrels per day (bpd) of oil equivalent is currently produced from Canada's oilsands and this is expected to reach 3 million bpd by 2020. Oilsands consist of bitumen, sand and water. The bitumen is separated from the sand and water before being upgraded to a synthetic crude oil. Upgrading the bitumen by coking yields liquid products that must be treated over a catalyst in the presence of hydrogen to remove S, N and other contaminants. The naphtha fraction of the liquid product, with boiling point < 177C, also contains significant quantities of olefins and diolefins that are stabilized by a low temperature (< 250C) catalytic hydrogenation before S and N removal. Although highly reactive, diolefins can be difficult to saturate and may undergo a polymerization reaction that results in carbon deposition on the catalyst. This leads to a rapid build-up of pressure drop in the reactor that ultimately results in early shut-down of the unit.