Third-generation silicon guard for coker naphtha hydrotreating

We recently launched our third-generation SiliconTrap™ catalysts – the TK-461 SiliconTrap and TK-467 SiliconTrap. They offer refiners attractive benefits including improved silicon removal, extended cycle lengths, and higher activity for sulfur and nitrogen removal – which translates into lower OPEX and increased unit profitability. In the following, we offer a brief overview based on a longer article first published in PTQ and used here with their kind permission. If you want to dive deeper into the science behind SiliconTrap, please download the full article on this page. 

Improved design for maximum silicon removal
Our latest SiliconTrap catalysts are built on an enhanced preparation technology that increases alumina surface roughness, which leads to a more uniform distribution of the active components across the catalyst. This uniformity not only boosts catalytic activity in key reactions such as HDS (hydrodesulfurization) and HDN (hydrodenitrogenation), but also increases contact between the feed molecules and the active sites.

The increased roughness provides additional surface area for silicon uptake per reactor volume, enabling the catalyst to capture and retain silicon contaminants more efficiently. By providing more sites for silicon binding, the catalyst can sustain its activity over extended cycle lengths, thus reducing downtime and operational costs. This dual benefit is fundamental to achieving higher overall efficiency, improved process reliability, and an extended catalyst life in refining applications. 

Commercial impact

The previous generation (TK-44x SiliconTrap) has been installed in more than 50% of coker naphtha units worldwide, with significant benefits – not least increased cycle lengths – commonly reported.
With the enhanced silicon uptake and catalyst activity of the new generation, even longer cycle lengths are possible. As an example, the new catalysts will extend a 24-month cycle by three to five months. Using a production rate of 20,000 BPD as an example, the additional production is close to 2 MM barrels, which will pay for the entire load of catalyst many times.
Furthermore, the improved HDS and HDN activity enables naphtha units to process feedstocks with higher sulphur and nitrogen levels. This enhanced activity mitigates potential downstream issues in reforming and isomerization units when processing more challenging feedstocks.

Best-in-class surface area with alumina carrier

The SiliconTrap series relies solely on high-purity alumina to maximize silicon pick-up efficiency, a key difference from other catalysts on the market that incorporate silica (SiO₂) into their formulations. Because Topsoe’s new catalysts are free of SiO₂, they ensure all components contribute effectively to adsorption and maximize silicon trapping capability. Our alumina-based formulation ensures the highest available silicon capacity per unit volume in the industry, validated through side-by-side field testing and pilot trials.

Our new silicon guard system is designed to integrate seamlessly into existing units, providing refineries with an efficient, reliable and high-performing defense against silicon fouling. With the new generation of SiliconTrap catalysts we want to help refiners run cleaner, safer and more economically, while breaking new ground in silicon removal technology.


Key benefits of the SiliconTrap silicon guard catalysts:

• Catalyst Protection: By removing silicon contaminants, the system extends the cycle length of hydrotreating and reforming catalysts, reducing replacement costs.
  
  
• Operational Efficiency: Refineries can avoid unplanned shutdowns caused by silicon-related fouling, ensuring smoother operations.
  
  
• Improved Product Quality: The system ensures that treated naphtha meets stringent quality specifications for downstream processing or blending.
  
  
• Cost Savings: Reduced maintenance and catalyst replacement expenses translate to significant cost savings for refiners.