Selecting the right hydrocracking (HCU) catalyst depends on generating reliable, representative data. A critical factor in achieving this is pilot‑plant configuration. In commercial hydrocracking operations, the performance of the first stage directly influences the second, making it essential to accurately capture this interaction during testing.
To address this, we have developed a new reactors‑in‑series pilot plant setup, specifically designed to better replicate true two‑stage hydrocracking conditions at pilot scale.
A Configuration That Reflects Reality
Our new system connects hydrotreating and hydrocracking stages in series, enabling a more realistic simulation of commercial operation. This configuration allows for improved understanding of how catalysts perform not only individually, but as part of an integrated system.
How the System Works
The pilot plant is designed to closely mimic industrial hydrocracking processes:
- Stage 1 – Hydrotreating: Removes contaminants such as nitrogen and sulfur, preparing the feed for the downstream process
- Stage 2 – Hydrocracking: Converts heavy fractions into lighter, higher‑value products
- Interstage sampling: Enables analysis of the hydrotreated stream before it enters the hydrocracking catalyst
- Seperate stage control: Allows precise tuning and evaluation of each stage’s performance and their interactions
- High‑pressure gas/liquid separation: Provides improved control over liquid product collection and analysis
Enabling Better Catalyst Evaluation
This advanced configuration makes it possible to address key questions in catalyst development and selection:
- How effectively does the pretreating catalyst control nitrogen slip?
- How does interstage feed quality influence hydrocracking activity?
- How do pretreating and hydrocracking catalysts perform together as a system?
- What is the impact on conversion, yield structure, hydrogen consumption, and final product quality?
By linking both stages in a single, integrated setup, the pilot plant provides deeper insight into the relationships between process conditions, feed quality, and catalyst performance.
From Catalyst to Catalyst System
In hydrocracking, evaluating catalysts in isolation is no longer sufficient. The key question is not only which catalyst delivers the highest conversion, but rather which catalyst system performs best under realistic process conditions.
Our reactors‑in‑series pilot plant is designed to answer exactly that supporting more informed decisions in catalyst screening, process development, and commercial catalyst selection.
Watch the video of our colleague Rosa to see the reactors‑in‑series pilot plant in operation and learn more about how it enables more representative hydrocracking catalyst testing.
