

Z-CAT HP™ LPG Olefins and Gasoline Octane

Enhancement Additive
DESCRIPTION

Z-CAT HP is a high activity version of INTERCAT’s pentasil additive, Z-CAT Plus. Both of these additives
are based on the use of ZSM-5, a member of the pentasil family of crystalline zeolites. These catalytic
materials are characterized by a five-membered ring structure with a 5.2 Angstrom port. This structure
is highly selective for cracking gasoline range normal olefins which would normally hydrogenate to
low octane normal paraffins. The products of this highly selective cracking are predominantly LPG
olefins with no increase in yields of C2 or lighter. In addition to the boost in LPG olefins, PENTA-CAT
additives also increase gasoline octanes through preventing the formation of low octane normal
paraffins.

The benefit of the Z-CAT HP over other manufacturer's ZSM-5 additives is its matrix structure. The
pentasil crystals are incorporated into an improved INTERCAT proprietary matrix that is designed to be
catalytically inert whilst allowing easy access to the highly active pentasil crystals.

Z-CAT HP is recommended over Z-CAT Plus in cases where a large amount of Z-CAT Plus is indicated to
achieve refinery objectives. Using Z-CAT HP in these circumstances will alleviate the possibility of
equilibrium catalyst MAT activity dilution due to adding large quantities of additive.

Particle size distribution and bulk density have been optimized to be compatible with all commercially
available FCC catalysts. Z-CAT HP has been pretreated to maximize its resistance to attrition and, on
an as-received basis, it is equal to or better than that of the hardest FCC catalysts available.

TYPICAL PROPERTIES PACKAGING

Attrition Resistance (ASTM D5757) 1.0 55 gallon drums - 330 lbs / 150 kg each
Surface Area, m2/g 85 Bulk bins or Big bags - 2,000 lbs / 1,000 kg each
ABD, g/cc 0.75 Bulk Truck
LOI (1 hour @ 1000°C), wt% 6
Na2O, wt% 0.15
Particle Size Distribution
0-20 microns, wt% 1
0-40 microns, wt% 8
Average Particle Size, microns 92


Z-CAT HP is covered by U.S. Patents #5,190,902, #5,288,739 and other patents.
Version 4.1
INTERCAT
P.O. Box 412, Sea Girt, NJ 08750 USA Technical information and data regarding the composition, properties or use of the products described
herein is believed to be reliable. However, no representation or warranty is made with respect thereto,
(732) 223-4644, 1-800-346-5425 except as made by INTERCAT in writing at the time of sale. INTERCAT cannot assume responsibility for any
FAX (732) 223-3447 patent liability which may arise from the use of any product in a process, manner or formula not designed
and produced by INTERCAT.
e-mail: info@intercatinc.com
www.intercatinc.com
Data Sheet - Z-CAT HP 4.1.doc 2002-09-02
ZSM-
ZSM-5 Technology Summary:

ZSM-5 is a shape-selective zeolite used in the FCC process for improved

gasoline octane and increased light olefins. In 1984, Grace Davison introduced
Additive-O, the first FCC additive to incorporate ZSM-5. Additive-O offered
refiners the ability to respond to the octane shortfall created by the phase-out of
lead from gasoline.
Since the introduction of our first ZSM-5 additive, Grace Davison has continued
to develop products with even higher activity to meet the demands of the refining
industry. Our ZSM-5 additive product portfolio includes OlefinsExtra (O-HS™) as
well as the most widely used ZSM-5 additive in the industry, OlefinsMax.
Recently, Davison successfully commercialized the next generation of ultra-high
activity additives, OlefinsUltra. All three products contain unique matrix
technology that ensures maximum zeolite activity, stability and utilization.
Additive physical properties (attrition resistance, average bulk density and
particle size distribution) are designed to be compatible with the FCC catalyst.

Product Portfolio:

OlefinsExtra contains a moderate level of ZSM-5 crystal and is an excellent

choice for refiners wishing to achieve the maximum increase in gasoline octane
with a moderate increase in light olefins selectivity.

OlefinsMax is recommended for refiners who desire high yields of light olefins
and octane boost that would otherwise require higher concentrations of less
active ZSM-5 additives. OlefinsMax is an option for units operating under a cat to
oil constraint.

A breakthrough in matrix technology has allowed the introduction of the novel,

ultra-high activity additive, OlefinsUltra. OlefinsUltra is the most active ZSM-5
FCC additive currently available on the market and contains the most ZSM-5
crystal allowable under a new license agreement. OlefinsUltra is the ideal choice
for refiners wishing to maximize the production of light olefins, especially
propylene from the FCC unit where very high levels of conventional additives
would be required that would otherwise result in dilution of the circulating catalyst
inventory. OlefinsUltra applications around the world continue to increase as the
refining industry turns to ultra-high activity ZSM-5 additives to more cost-
effectively meet their light olefins requirements.

Applications:
Applications

• Raise propylene yield for petrochemical applications

• Increase butylenes yield for alkylation, MTBE
• Increase gasoline pool octane and reduce sensitivity
• Maintain FCC gasoline octane while in an LCO maximization mode

Typical Properties
Properties:
ties
OlefinsExtra OlefinsMax OlefinsUltra
Activity Relative to OlefinsMax (%) 70 100 180
Sodium, wt% < 0.1 < 0.1 < 0.1
Davison Index 5 5 5
ABD, g/cc 0.76 0.74 0.74
APS, microns 75 75 75
0-20 microns,wt% 0 0 0
0-40 microns,wt% 8 8 8
Packaging:

• 350 lb steel drums

• 1 ton flow bins or super sacks
• 20 ton pneumatic tank trucks
• Preblended with fresh catalyst shipments

Technical Service:

• Selection of the optimal usage rate

• Assistance during additive testing
• Monitoring unit performance
• Analyzing equilibrium catalyst during the test period
• Injection system equipment

The information contained herein is based upon our testing and experience and
is believed to be accurate. Since operating conditions may vary and since we do
not control such conditions, we must disclaim any warranty, express or implied,
with regard to results to be obtained from the use of our products or with regard
to application of Davison techniques.

For more detailed information on Davison's Light Olefins products and services,
current propylene market analysis, as well as training modules and our technical
library, please refer to the Light Olefins section in e-Catalysts.com.
 INTERCAT Additive Addition System
50 - 200 ft3 Style 4, With IMS Controller.

Installation Instructions & Utility Requirements

Pre-Assembly Checklist.
Before starting to assemble the system, check that all the parts are present and correct. The
addition system shipment should contain the following parts:
1. The main vessel, complete with most piping attached.
2. The catalyst discharge line, shipped separately.
3. The loadcell skid, complete with dummy loadcells and real loadcells.
4. A couple of boxes of miscellaneous parts including:
a) 2” re-inforced rubber loading hose
b) Two 1” stainless steel flexible hoses
c) The vessel manway cover and clamps
d) A collection miscellaneous bolts, etc.
5. A crate containing the IMS Controller.

Step 1 - Addition System Assembly.

A crane is normally needed for this part of the installation.
• Place the loadcell skid into its final location. Bolt the base plate to the ground using the
holes at end of base plate arms. (See Photograph #1) The vertical leg protruding from the
base will be used to mount the IMS Controller, and this should be set to face North, if at all
possible.
• Lower the vessel onto the loadcell skid, and bolt the legs to the loadcell mounting plates.
Note that the vessel can be rotated on the base to face any direction required.
• Attach the catalyst discharge line to the addition system as shown in Photograph #2. Mount
the IMS Controller onto the stand provided on the 3” vertical pipe which protrudes from the
base. Locate the IMS Controller door bolts and keys and keep in a safe location.

Step 2 - Piping Connections.

• Connect the plant air supply to the vessel using the supplied 1” screwed stainless steel
flexible hose. (See Photograph #3.)
• Connect the catalyst line from the addition system to the FCC unit using the supplied 1”
flanged stainless steel flexible hose. (See Photograph #2) IMPORTANT NOTE! This hose
must be run straight, in either a horizontal or a vertical direction, and must have no kinks in
it whatsoever. This is very important to prevent erosion of the flexible hose. This line
should be connected to the existing catalyst loading line to the regenerator. Additional
transport air should be provided if the line size is increased above one inch.
• Run a ½ to ¾ inch instrument air supply to the solenoid valves under the IMS Controller.

Page 1
Step 3 - Electrical Hookup.
• Connect both the addition system vessel and the base plate to ground (Earth).
• Run a 110 VAC electrical power supply with earth (ground) connection to the IMS
Controller. This supply should be run into the IMS Controller using the first port from the left
on the bottom of the IMS Controller box. This supply should have an on/off switch local to
the Controller, and should be wired to the fuses and ground (earth) connections on the left
hand side of the terminal strip. The IMS Controller is normally shipped with wire tails
already on these connections. (See Terminal Strip Diagram, attached.)

Step 4 - Instrument Hookups.

• Connect the loadcell wires to the IMS Controller. The three loadcell cables, one from each
loadcell are routed through the base of the loader up into the 3 inch pipe which protrudes
from the base. They emerge from this 3” pipe just below the IMS Controller. These cables
need to be run in flexible conduit to the right hand open connector under the IMS Controller
and connected to the terminal strip as follows:
a) The three red wires each to a +EXC connector on the terminal strip.
b) The three black wires each to a -EXC connector on terminal strip
c) The three green wires (+SIG) each to a separate connection 3 on the bottom of one
of the Loadcell Signal IS Barriers.
d) The three white wires (-SIG) each to a separate connection 4 on the bottom of one
of the Loadcell Signal IS Barriers. (The green and white wires from each loadcell
cable should be connected to the same barrier.)
e) All shielding to earth (ground).
(See diagram of terminal strip, attached.)
Note that the IMS Controller is shipped with small lengths of green and white wire shorting
out connections 3 & 4 on the IS Barriers to earth. These wires are just there to protect the
IMS during shipping, and must be removed before the loadcells are connected up.
Note also that each loadcell is connected individually. The numbering of the loadcells will
be determined during commissioning.
• Install the IMS Power Supply. This power supply belongs inside the IMS Controller box, but
has been removed for shipment. It is shipped inside a cardboard box which is located
inside the IMS Controller, behind the bracket on the top right hand side of the controller.
Remove the Power Supply from its box, and slot it into the connector just behind its shipping
location, and use the same bracket to secure it in place.
• Run ¼” flexible tubing from the solenoid valves under the IMS Controller to the Robin Valve
and the ESD Valve. Three small bore flexible instrument air lines should be run from the
IMS Controller to the valves on the base of the loader, as follows:
a) Two lines should be run from the left hand solenoid valve under the IMS Controller to
the Robin Valve on the base of the loader. The Robin Valve is the lower of the two
valves mounted on the catalyst outlet line at the bottom of the addition system vessel -
(See Photograph #4.)

Page 2
 − The top connection on the Robin Valve should be connected to Port No. 2 on the
solenoid valve.
− The bottom connection on the Robin Valve should be connected to Port No. 4 on
the solenoid valve. (Note that this connection on the Robin Valve is 1/8 inch
NPT.)
The ports on the solenoid valve are numbered, with Port No. 4 being the one that is
closest to the electrical connection.
b) One line should be run from the outlet of the solenoid valve on the right hand side of the
air manifold under the IMS Controller to the pneumatic valve actuator which is attached
to the ball valve immediately under the vessel cone. (The upper of the two valves
mounted on the catalyst outlet line at the bottom of the vessel.) A stainless steel 3 way
valve is normally fitted to the ball valve actuator, and the air line should be run to the top
connection on this 3 way valve. (See Photographs #5 and 6) Note that this actuator is
fitted so that the ESD ball valve closes on air failure.
• Hook up any wires connecting the IMS Controller to the refinery DCS System. (Note that
these connections are completely optional, and are not required.) If these connections are
to be made, the wires should all be run into the IMS Controller using the second port from
the left on the bottom of the IMS Controller box. The available signals are as follows:
a) 4-20 mA output signal for weight in vessel: Connect to terminals +/- AQ1 on
terminal strip.
b) 4-20 mA output signal for target addition rate: Connect to terminals +/- AQ2 on
terminal strip.
c) Common remote alarm indication: Connect to terminals +Q005 and -24 on terminal
block.
d) Online / Offline indication: Connect to terminals +Q004 and -24 on terminal block.
e) 4-20 mA input signal for remote setpoint control. (This module is not normally fitted
unless specifically requested.) Connect to terminals +/- AI1 on terminal strip.

Step 5 - Replacement of Dummy Loadcells.

This step should only be carried out just prior to commissioning, when all other work is
complete. A portable hydraulic jack is required for this step.
• The Addition System is normally shipped with dummy loadcells in place to ensure that the
real loadcells are not damaged during shipment and installation. The real loadcells are
strapped to the side of the base, and these are normally installed once all the mechanical
work on the addition system is completed. Jacking points are provided on the addition
system vessel legs to support the vessel while the loadcells are being replaced. It is very
important that the loadcells are treated gently during this installation procedure. Note that
the loadcells must be fitted with the arrows on the end pointing down. The writing on the
labels should be the right way up.
IMPORTANT: No electrical welding should be carried out on the addition system once the
loadcells are fitted in place. The loadcells are easily damaged by any stray current from the
earth connection of an electrical welder.

Page 3
Step 6 - Pre-Startup Checks.
These steps should only be carried out just prior to commissioning, when all other work is
complete.
• Climb up the vessel ladder, and open the top hatch on the vessel. Reach inside and check
that the trickle valve on the cyclone dip leg is free to move, and is seated properly (See
Photograph #7). Note that this valve is sometimes taped in the closed position for shipping
using duct tape. Take care not to drop any debris into the vessel during this procedure.

• Visually check that the inside of the vessel is free from any foreign materials, then fit the
vessel manway cover and firmly tighten the mounting clamps.

At this point, the system is ready for checkout, calibration and commissioning by your
INTERCAT Technical Service Engineer.

Page 4
 Appendix 1.

Addition System Utility Requirements.

Plant Air
There is one plant air connection required on this vessel. This is a 1” diameter line which is
connected to the air pressure regulator manifold on the side of the loader. This supply is used
for pressurizing the vessel, powering the vacuum eductor, and for carrier air. Design air
3 2
consumption is a maximum of 210 scfm (356 nm /hr) at 100 psi (7 kg/cm ) when the eductor is
3
running, and about 15 scfm (25 nm /hr) under normal operation. The supply line to the loader
can normally be 1", but should be increased to 1.5" or 2" if the supply pressure is less then
70psi, or if the line length will exceed 30 feet.

Electrical Power
There is one electrical power connection required by the INTERCAT Additive Addition System.
This is a 110 or 200 Volt AC supply (200 Watt max) to the IMS Controller. This wire should be
run into the IMS Controller using the first port from the left on the bottom of the IMS Controller
box. This supply should have an on/off switch local to the Controller, and should be wired to
the fuses and ground (earth) connections on the left hand side of the terminal strip.

Instrument Air
There is one instrument air connection required on this vessel. This is a small bore (typically ½"
or ¾" ) instrument air supply to the air filter on left side underneath the IMS Controller. The
connection on the IMS is ¼" NPT. Instrument air consumption is negligible."

Page 5
 Appendix 2 - Diagram of IMS Controller Terminal Strip.

Standard 110V power outlet for PLC

Grounding Terminal
|
Incoming Power should be connected

L1
installed prior to shipping to indicate
to these connections. (Wire tails

L2 O

Programmer.
|
correct location.)

GRND

Main Power Fuse

L2 L1
L2 L1
L2 L1
Ground Ground
Ground Ground
Ground Ground
-24 +24
-24 +24
-24 +24

IMS Controller Terminal Strip

%I009 %I001
%I010 %I002

Connection Diagram
%I011 %I003
%I012 %I004
%I013 %I005
%I014 %I006
%I015 %I007
%I016 %I008
One loadcell should be connected to each level of

%Q005 %Q001
%Q006 %Q002
Connect Loadcell Black and Red wires.

%Q007 %Q003
%Q008 %Q004
-%AQ01 +%AQ01
Back wires to -EX1
Red wires to +EX1

-%AQ02 +%AQ02
terminal strip.

-%AQ03 +%AQ03
-%AQ04 +%AQ04
-%AI01 +%AI01
-5 +5
-5 +5
One loadcell should be connected to each barrier.

Connect Loadcell Signal wires to these barriers.

-5 +5
-15 +15
-15 +15
White wrires to connection #4
Green wires to connection #3

-15 +15
+EX1 +EX1 +EX1
-EX1 -EX1 -EX1
Relay for %Q004

: Barrier: Loadcell #1 +/- Signal :

: Barrier: Loadcell #2 +/- Signal :
: Barrier: Loadcell #3 +/- Signal :
: Barrier: + Excitation :
: Barrier: - Excitation :
0 0 Barrier: Robin Valve 0 0
0 0 Barrier: ESD Valve 0 0

Page 6
Appendix 3 - Construction Photographs
3
Photograph No.1 - 50ft Loader Loadcell Skid

Photograph No.1 - 200ft3 Loader Loadcell Skid

Page 7
Photograph No.2 - Catalyst Loading Line

Page 8
Photograph No.3 - Plant Air Inlet Connection

Photograph No.4 - Robin Valve Connections

Page 9
 Photograph No.5 - ESD Valve Location

Photograph No.6 - ESD Valve Connections

Page 10
 Photograph No.7 - Cyclone Trickle Valve
The photograph below illustrates what the cyclone trickle valve looks like before installation.

Page 11
Appendix 4 - Process Connection Sketch

Page 12
 ATM. ISBL OSBL

3"
3" 2"
1½"
10"

3"
3"

Eductor

Load
Cells 2"
A/B/C
R1
R2
R3
1"
Loading
1" Line

4"
1"
PI 1" 1" 1"
To FCC
1"
Plant Air
PI
1"

FC

Instrument ½" IMS TITLE

Air Controller
Additive Addition System
with Cyclone - Style 4
DATE DWG NO REV
23, April, 2001 P&ID 4-01 4
By SIZE SHEET
MWB A4 1 of 1