Maximize Utilization of High-activity Hydrotreating Catalysts

Refiners face increasing pressure to balance profitability, reliability, and sustainability—all while processing heavier, more variable crudes. High-activity hydrotreating catalysts hold the key to extending run length and improving margins, but their success depends on more than formulation. From selection and reactor design to handling, loading, and monitoring, every decision affects utilization and cycle performance. As cycle lengths increase and feeds become more demanding, even small process deviations can shorten catalyst life or erase expected gains.

This article explores:

  1. How design and loading practices influence catalyst distribution and activity.
  2. Why feed quality and contaminant control are critical to run length.
  3. How integrated planning, monitoring, and digital twins can extend catalyst life and reduce unplanned downtime by up to 50%.