FCC Catalysts & Additives

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product stewardship summary CAS No. Mixtures EINECS No. Mixtures FCC Catalysts and Additives

Introduction fuels from the high boiling range cut of Table of Contents Albemarle Corporation provides fl uid heavier and cheaper crude oils. In addition to these FCC catalysts, Introduction catalytic cracking (FCC) catalysts to the oil refi ning industry. Albemarle Albemarle has six FCC performance Description and Properties has provided the industry with additives marketed with the following TM Uses technology leading catalysts for over product names: BCMT-500 , BCMT- TM TM TM Health Information 30 years and has nine FCC Catalysts DC , BCMT-MD , PROvantage , TM TM that are actively marketed today. DuraZOOM , and SMOOTHFLOW . Exposure Potential They are AFXTM, ACTIONTM, AMBERTM, Performance additives address various Environmental Information CORALTM, UPGRADERTM, UPGRADER FCC unit issues such as propylene Physical Hazards R+TM, GO-ULTRATM, AMBER MDTM, and maximization, increasing octane,

TM bottoms cracking and accessibility Derivation/Manufacturing UPGRADER MD . These catalysts are used to convert Regulatory Information petroleum crude oil Product Stewardship to gasoline, diesel Conclusion fuel and valuable petrochemicals. Note The FCC process References supplies 40-50% of the world’s demand for gasoline. The FCC process produces higher yields of clean gasoline than thermal cracking processes and higher octane than hydrogen rich cracking process improvements, and fl uidization (or such as Hydrocracking. Using a well- circulation) problems. TM chosen FCC Catalyst allows a refi nery The Albemarle products KDSOx , TM TM TM to maximize the yield of high value DuraSOx , SOxMASTER , KOC-15 ,

Page 1 of 6 ELIMINOxTM, R-975TM, and SCAVENGERTM maintaining high levels of conversion Contaminants such as nickel, vanadium, are environmental additives. These to valuable products. Also, the global iron and other metals can deactivate the additives are used to remove sulfur demand for high-quality diesel is catalyst or alter the process reactions from gasoline, and environmentally expected to grow. and thus reduce the conversion rate of hazardous materials such as carbon The catalytic monoxide (CO), sulfur oxides (SOx) cracking process and nitrous oxides (NOx) from produces high yields refinery emissions. of gasoline with good octane rating. Description and Properties FCC units are also The FCC Catalysts are stable off-white, playing an increasing light yellow or yellow powders. They important role in have a negligible solubility in water. meeting the growing They are composed of zeolite, silica, worldwide demand alumina, clay and binder. Almost for proplyene. always the zeolites contained in the FCC FCC catalysts and catalyst are rare earth, predominantly additves such as AFX, DuraZOOM, and the longer length carbon chain in the lanthanum compound. Additionally, PROvantage help refiners produce this feedstock to the more valuable short some additives may contain magnesium valuable product. Propylene is in high chain fuels. Albemarle’s premier FCC oxide, platinum, or other application demand in the growing petrotrochemical catalyst designed to crack these heavier specific chemicals. industry as it is a building block in feeds, UPGRADER, helps reduce the a wide variety of synthetic plastics negative effect of these contaminants. including Albemarle’s performance additives, polypropylene BCMT-500 and BCMT-MD provide fast and other useful remedies for the unfavorable effect of polymers. iron contamination. The requirements During the refining process, coke, a for gasoline quality carbon-rich byproduct, deposits on the continue to change, catalyst. To restore the catalyst activity, and the refiners the coke must be burned off in a FCC must comply with regenerator. Combustion promoter the mandated additives allow better control of the octane ratings. regenerator temperature and reduce or FCC Catalysts eliminate afterburn. Afterburn creates and additives are high temperatures that may cause Uses used to maximize quality target fuel serious metallurgical damage to parts of Fluid catalytic cracking (FCC) is the production, such as gasoline or diesel, the unit, causing unexpected shutdowns most important technology in modern while minimizing undesirable cuts of and significant losses due to downtime. continuous process refining. The FCC hydrocarbons. They can increase the Use of FCC additives such as KOC-15 Catalysts crack high boiling range octane in gasoline production. They and ELIMINOx can improve stability of petroleum hydrocarbons into gasoline, allow refineries to process heavier operation by reducing or eliminating diesel fuel, propylene and butylenes. crude sources with higher levels of afterburn, as well as lower the rate of Refiners are always under pressure to contaminates into clean fuels. This emission of harmful compounds from process heavier residual feedstock while improves the refineries’ profitability. the regenerator such as CO and NOx.

Page 2 of 6 FCC additives also help refineries compounds can result in bronchitis recommended when dusty or irritating meet increasingly stringent global and bronchopneumonia. conditions exist. environmental regulations on sulfur Please consult the product Material Please consult the product Material content in plant atmospheric emissions Safety Data Sheet for recommended Safety Data Sheet for recommended and product streams, such as gasoline. personal protective equipment and personal protective equipment and They are proven to significantly reduce further information. further information.

Exposure Environmental Information Potential Three of the FCC products, SCAVENGER,

The FCC Catalysts R-975 and SOxMASTER are toxic could contain to aquatic organisms and must be components that labeled as Environmentally Hazardous may have exposures Substances. These products can be limits established by handled properly in transportation, individual countries, storage and use, preventing release to including so called public waters such as lakes, streams, derived no effect ponds and oceans. levels (DNELs) for Physical Hazards human health and predicted no effect The FCC Catalysts are all stable SOx emissions from FCC units. SOx is concentrations for the environment that materials under normal handling and the main precursor in the formation are being derived under the European storage conditions. Extremely high of acid rain which is a serious global REACH regulation. These are listed on temperatures and dust formation should environmental concern. Refineries can the product material safety data sheet. be avoided. also mitigate the formation of NOx Workplace monitoring and surveillance emissions by using FCC additives such of environmental releases must be as ELIMINOx. Reducing NOx decreases conducted to ensure air pollution and ground level ozone. that workers and the Emissions from automobiles contribute environment are not to ozone production and air pollution overexposed to those or smog. By controlling sulfur in components for which gasoline while maintaining octane exposure limits have and gasoline volume from the FCC, been established. additives such as SCAVENGER and Good industrial R-975 allow refiners to maximize the hygiene practices quantity of clean gasoline they can and normal industrial sell into their respective markets. precautionary measures to prevent contact Health Information should minimize the health risk when Derivation/Manufacturing The FCC Catalysts have low toxicity. handling these products. In addition Albemarle Corporation manufactures Minor effects from product dust may to eye protection, workers should the FCC Catalysts at several locations; occur such as eye, skin and respiratory use protective gloves and protective Bayport and Pasadena, TX as well as irritation. KDSOX, DuraSOx and clothing when skin contact or clothing Amsterdam, Netherlands. SOxMASTER contain vanadyl sulfate. contamination is possible. The use of Repeated inhalation of vanadium a NIOSH approved respirator is also

Page 3 of 6 Regulatory Information importer, has pre-registered all and oils and light olefins, such as propylene. registered the main components of Specific additives can also be employed Three of the FCC products, SCAVENGER, the FCC catalysts. Albemarle is deeply to solve production problems in the R-975 and SOxMASTER are regulated for involved in Industry activities to ensure FCC unit such as fluidization issues, transport purposes as Environmentally timely registrations with deadlines afterburn and metal poisoning. Gasoline Hazardous Substances. SCAVENGER depending on volume threshold put specifications are tight due to stringent and R-975 are also Marine Pollutants. on the EU market and/or substance global enviornmental regulations. The rest of the FCC Catalysts are not characteristics. FCC Catalysts and Additives help refineries maintain compliance with Product these regulations with sulfur reduction Stewardship and higher octanes in gasoline. FCC

Albemarle Catalysts and Additives are also Corporation is instumental in reducing emissions of the committed to environmentally hazadous substances manage FCC NOx and SOx from FCC Units. Catalysts so Note that they can be safely used by This document provides general our customers. information about FCC Catalysts and Our relationships does not supplant or replace required regulatory and/or legal communication regulated for transportation purposes. with our customers encourage documents, nor is it intended to provide The FCC Catalysts are in compliance with communication about safety and an in-depth discussion of health and TSCA and some are also in compliance environmental stewardship, and we safety information. Always consult the with other international countries’ work with them to minimize the risks product’s material safety data sheet, chemical inventories. of personnel exposure and spills. product label and technical data sheet Three of the FCC Additives, KOC-15, Albemarle is organized and staffed before using the chemical. SOxMASTER and SCAVENGER are with experts in toxicology, regulatory classified under the Canadian Workplace compliance, industrial hygiene, and Hazardous Material Information System emergency response to investigate (WHMIS) as Class D materials in Division and provide advice regarding 2B. All of the other products are not appropriate corrective actions if controlled under WHMIS. such incidents occur. The Emergency Planning and Community Conclusion Right-to-Know Act (also known as SARA Title III or EPCRA) classifies the FCC FCC Catalysts and Additives are the Catalysts as being acute health hazards. cornerstone of the modern petroleum The products KDSOX, DuraSOx and refinery, providing high quantities SOxMASTER are also listed as chronic of valuable fuels and petrochemical hazards in addition to the acute feedstocks, from a varying quality of health hazards. feedstock. The FCC catalyst is the key Under the European “REACH” element in converting these heavy Regulation, Albemarle Catalysts BV, feedstocks, containing contaminant acting as EU manufacturer and/or metals, into clean gasoline, diesel fuel

Page 4 of 6 References

Fluid catalytic cracking. (n.d.). In Albemarle Corporation Americas MSDS Albemarle Catalysts Company bv MSDS Wikipedia. Retrieved July 30, 2010, from Date: 12-Apr-2010, Product Name: Date: 01-Mar-2010, Product Name: http://en.wikipedia.org/wiki/Fluid_ FCC Catalyst: Access; Action; Advance; KOC-15; KOC-18 catalytic_cracking Amber, Aztec; Centurian; Cobra; Conquest; Coral; Eclipse, Emerald, Albemarle Catalysts Company bv MSDS Nee, J., Harding, R., Yaluris, G., Cheng, Expander; Horizon, (Octa)Vision; Opal; Date: 17-Dec-2009, Product Name: ISOBOOST; W., Zhao, X., Dougan, T. and Riley, J. Provantage, Ruby, Sapphire; Smoothflow; K-1000; K-2000; B.O.O.S.T.; Z.O.O.M.; Super 2004. Fluid Catalytic Cracking (FCC), Upgrader; GO-ULTRA B.O.O.S.T.; DuraZoom; ISOZOOM Catalysts and Additives. Kirk-Othmer Encyclopedia of Chemical Technology. Albemarle Corporation Americas MSDS Albemarle Catalysts Company bv MSDS Date: 12-Feb-2010, Product Name: Date: 22-Oct-2009, Product Name: KDSOX; Albemarle PowerPoint Presentation SK-SCS; ADC; AFX-1F; AFX-8F SOXDOWN; KDSOX-ZH; DURASox – 2007 Albemarle Overview FCC Catalyst Technology Training Presentation Albemarle Corporation Americas MSDS Albemarle Catalysts Company bv MSDS Date: 11-Aug-2010, Product Name: BCMT; Date: 09-Sep-2008, Product Name: Fluid Albemarle PowerPoint Presentation BCMT 100; BCMT 100J; BCMT 500; Catalytic Cracking Additive – SOxMASTER – 2008 Maximum LCO with Albemarle BCMT MD superior FCC Catalysts Albemarle Catalysts Company bv MSDS Albemarle Corporation Americas MSDS Date: 27-Sep-2007, Product Name: ELIMNOx Albemarle Brochure – ACTION Catalysts Date: 11-Aug-2010, Product Name: that raise the octane value of FCC KOC-15; KOC-18 gasoline with minimal loss of volume, November 2006 Albemarle Corporation Americas MSDS Date: 09-Jun-2010, Product Name: Albemarle Brochure – Comprehensive ISOBOOST; K-1000; K-2000; B.O.O.S.T.; sulfur control in the FCC, March 2006 Z.O.O.M.; Super B.O.O.S.T.; DuraZoom; ISOZOOM; ZOOM GPC Albemarle Brochure – Boosting middle distillate production in FCC, Albemarle Corporation Americas MSDS November 2008 Date: 20-Jul-2010, Product Name: KDSOX; SOXDOWN, KDSOX-ZH; DURASox Albemarle Technical Data Sheet – OPAL Resid catalyst for low bottoms Albemarle Corporation Americas MSDS and low coke Date: 04-Nov-2007, Product Name: SOxMASTER Albemarle Technical Data Sheet – Want to increase the propylene production Albemarle Corporation Americas MSDS from your fluid catalytic cracking unit?, Date: 12-Aug-2010, Product Name: FCC-19-09 R 975

Albemarle Technical Data Sheet – Albemarle Corporation Americas MSDS UPGRADER Improve you FCC Unit Date: 11-Aug-2010, Product Name: residual feedstock processing ELIMINOx; ENT-84plus; EN-3; EN-4

Albemarle Technical Data Sheet – Albemarle Catalysts Company bv MSDS SMOOTHFLOW The solution to FCC Date: 19-Feb-2010, Product Name: catalyst fluidization problems FCC Catalyst: Access; Action; Advance; Amber, Aztec; Centurian; Cobra; Albemarle Technical Data Sheet – Conquest; Coral; Eclipse, Emerald, Total Olefins Management, Minimizing Expander; Horizon, (Octa)Vision; Opal; gasoline olefins Provantage, Ruby, Sapphire; Smoothflow; Albemarle Technical Data Sheet – Upgrader; GO-ULTRA BCMT-500 FCC additive for the treatment Albemarle Catalysts Company bv MSDS of iron poisoning Date: 27-Jul-2007, Product Name: Fluid Albemarle Technical Data Sheet – Catalytic Cracking Additive – BCMT KOC The flexible and effective way to lower afterburn in your FCC unit

Page 5 of 6 How to Contact Us You can write us for additional information at: Albemarle Corporation Or e-mail us at: [email protected] Responsible Care Coordinator 451 Florida Street Baton Rouge, LA 70801-1765

Albemarle Corporation is a member of the American Chemistry Council and, through ACC’s participation with the International Council of Chemical Associations (ICCA), has prepared this document to improve product stewardship within the chemical industry and with suppliers and customers. The information presented herein is believed to be accurate and reliable, but is presented without guarantee or responsibility on the part of Albemarle Corporation and its subsidiaries. It is the responsibility of the user to comply with all applicable laws and regulations and to provide for a safe workplace. The user should consider any health or safety hazards or information contained herein only as a guide, and should take those precautions which are necessary or prudent to instruct employees and to develop work practice procedures in order to promote a safe work environment. Further, nothing contained herein shall be taken as an inducement or recommendation to manufacture or use any of the herein materials or processes in violation of existing or future patent.

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