Minimizing Risks Associated with First-Time Use of a New C2 Tail-End Catalyst

In an Olefin Plant, one of the most important processing steps involves the catalytic removal of acetylene in the ethylene product.  Failure of the catalyst in this purification step can have significant economic and environmental consequences, as off-spec ethylene will force flaring or worse case a shutdown of the plant.    Accordingly, any changes to the acetylene removal system, including use of a new catalyst, are subject to a high degree of review and reservation by the operations staff.  In this case, we review the steps taken by one olefin producer in their quest to install a new C2 tail-end catalyst.  The case study describes the steps taken by a diverse team from operations, technology, and catalyst suppler to address the potential risks.  Mitigation steps were identified and implemented to minimize or eliminate the potential for off spec production, including actions such as specific lab testing at unit conditions, start-up support, staggered implementation, and post installation optimization. 

 This presentation describes a case study highlighting of the risks assessed, potential mitigation measures and the positive results of implementing the catalyst change-out. Catalysts normally last 10 to 20 years, so that by the time a plant gets around to changing their catalyst, they are dealing with the next generation of selective hydrogenation catalyst.  So the material is relevant to anyone replacing catalyst due to end of life