Module 1 - Catalyst Types

Module from the Hydroprocessing Operations Curriculum curriculum.

HYDROPROCESSING CATALYST TYPES & SELECTION · Learning Objectives · 1. Identify the three primary hydroprocessing catalyst families (CoMo, NiMo, NiW) 2. Understand the role of active metals, promoters, and catalyst support 3. Select appropriate catalyst for specific services (HDS, HDN, HDA, HCK) 4. Interpret catalyst vendor specifications and performance guarantees 5. Understand catalyst grading and bed loading configurations · Hydroprocessing Catalyst Families — Detailed Comparison

Catalyst	Active Metals	Support	Primary Reaction	Best Application	Operating Temp (°F)	H2 Pressure (psig)
CoMo/Al2O3	Cobalt oxide + Molybdenum oxide	γ-Alumina (high surface area, 150-300 m²/g)	Hydrodesulfurization (C-S bond breaking)	Naphtha HDS, diesel HDS, VGO pretreating	580-700	300-800
NiMo/Al2O3	Nickel oxide + Molybdenum oxide	γ-Alumina (150-300 m²/g)	HDN + deep HDS + aromatic saturation	Diesel ULSD (<15 ppm S), VGO HDT, pretreat for FCC	600-750	500-1500
NiW/Al2O3	Nickel oxide + Tungsten oxide	γ-Alumina or Silica-Alumina	Aromatic saturation + mild cracking	Lube hydrofinishing, white oil, food-grade wax	550-700	1000-2500
NiMo/Zeolite-Al2O3	Nickel oxide + Molybdenum oxide	USY Zeolite + Alumina binder	Hydrocracking (C-C bond breaking)	VGO hydrocracking to naphtha/diesel/jet	680-780	1500-3000
NiW/Zeolite-Al2O3	Nickel oxide + Tungsten oxide	USY Zeolite + Alumina binder	Selective hydrocracking	Maximum middle distillate (jet/diesel) selectivity	680-780	1500-3000
CoMo/SiO2-Al2O3	Cobalt oxide + Molybdenum oxide	Amorphous Silica-Alumina	Mild hydrocracking + HDS	VGO mild hydrocracking (20-40% conversion)	700-780	800-1500
Grading / Trap Catalyst	Low activity metals or inert	Large-pore alumina (300+ m²/g)	Metals/particulate capture	Top-bed protection in all reactors	Any	Any
Demetallization Catalyst	Low activity NiMo	Macro-porous alumina	HDM (Ni + V removal)	Resid hydrotreating, heavy feed protection	650-750	1000-2500
Catalyst Bed Loading Configuration — Typical Multi-Bed Reactor
Bed Position	Catalyst Type	Function	Volume (% of total)	Particle Size	Loading Method
Top of Bed 1	Inert balls (Al2O3)	Support / distribution	2-3%	3/4" to 1" diameter	Sock loaded, leveled
Upper Bed 1	Grading catalyst (large pore)	Trap scale, particulates, metals	5-10%	1/16" to 1/8" extrudate	Dense loaded (Densicat/Catapac)
Main Bed 1	CoMo or NiMo (high activity)	Primary HDS/HDN	30-40%	1/16" extrudate (trilobe/quadlobe)	Dense loaded, target ±2 lb/ft³ of spec
Main Bed 2	NiMo (high activity)	Deep HDS, HDN, aromatic saturation	30-40%	1/16" extrudate	Dense loaded
Bottom Bed (optional)	NiMo or CoMo (polishing)	Final product quality polishing	10-15%	1/32" or 1/16" extrudate	Dense loaded
Bottom support	Inert balls + screen	Prevent catalyst migration to outlet	2-3%	1/2" to 1" graduated	Hand placed, screen welded
Source: FOS Chief Files — Catalyst & Loading folder, Hydroprocessing Design Manual, Preactivated Catalyst Info, UOP Catalyst Information

Source: Hydroprocessing_Operations_Curriculum_v1.xlsx · Sheet: Module 1 - Catalyst Types

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