A Comparison of Laboratory Simulation Methods of Iron Contamination for FCC Catalysts

Two different methods of simulating iron contamination in a laboratory were studied. The catalysts were characterized using X-ray diffraction, N2 adsorption–desorption, and SEM-EDS. The catalyst performance was evaluated using an advanced cracking evaluation device. It was found that iron was evenly distributed in the catalyst prepared using the Mitchell impregnation method and no obvious iron nodules were found on the surface of the catalyst. Iron on the impregnated catalyst led to a strong dehydrogenation capacity and a slight decrease in the conversion and bottoms selectivity. The studies also showed that iron was mainly in the range of 1–5 μm from the edge of the catalyst prepared using the cycle deactivation method. Iron nodules could be easily observed on the surface of the catalyst. The retention of the surface structure in the alumina-rich areas and the collapse of the surface structure in the silica-rich areas resulted in a continuous nodule morphology, which was similar to the highly iron-contaminated equilibrium catalyst. Iron nodules on the cyclic-deactivated catalyst led to a significant decrease in conversion, an extremely high bottoms yield, and a small increase in the dehydrogenation capacity. The nodules and distribution of iron on the equilibrium catalyst could be better simulated by using the cyclic deactivation method.