Ketjen unveils commercial testing results for new SaFeGuard catalyst
Ketjen Corporation revealed additional commercial testing results for SaFeGuard™, their newly released FCC catalyst technology designed to minimize the effects of iron (Fe) poisoning while increasing activity and profitability. The details were presented this week at the 2025 AFPM Summit conference in Grapevine, Texas.
During a 30-day full commercial trial completed in July 2025, SaFeGuard™ achieved a 77% improvement in diffusion and catalyst accessibility with a 50% inventory changeout when compared to the current leading catalyst solution for processing iron-rich feedstocks. Further testing and predictive modeling suggest a full 100% inventory changeout could yield up to a 130% increase in accessibility delivering additional performance improvements.
SaFeGuard™’s performance in iron-rich environments was quantified using the Ketjen Accessibility Index (KAI). The index is a 10-point scale which measures the ability of hydrocarbon to diffuse into catalyst pores, an activity significantly impeded by the presence of high iron levels. An Accessibility Index on the lowest end of the KAI scale translates into a severe loss of catalyst activity. This is due to eutectic formation and nodule development associated with high iron levels that cover the surface pores of catalyst particles, inhibiting activity, resulting in higher dry gas (mainly H2) and poor bottoms cracking. In comparison, higher KAI scores are associated with lower contamination levels, leading to higher activity and lower dry gas and slurry yields. Stated more simply, higher KAI scores demonstrate greater accessibility, activity and profitability.
“The recently completed commercial trial of SaFeGuard™ demonstrated KAI scores ranging from +4 to 7 with a 50% changeover. These scores are 2-3 points above the leading solution for iron poisoning. At 100% changeover, modeling suggests SaFeGuard™ could achieve KAI scores above 8,” said David Leach, Vice President and General Manager, FCC at Ketjen. “In lab studies, SaFeGuard™ Fe tolerance was measured at 2.0 – 2.5 times that of the current leading solution, meaning it can handle more Fe than the previous highest performing product at a fixed KAI.”
In regard to yields, commercial testing showed SaFeGuard™’s ability to minimize the impacts of iron poisoning led to a more than 2.3% increase in the production of liquefied petroleum when processing iron rich feedstocks. A previous commercial test of SaFeGuard™, conducted in 2021 demonstrated similar results and achieved a more than 2% increase in gasoline production.
“While repeat commercial testing demonstrates SaFeGuard™’s ability to effectively address iron poisoning and increase profitability, this solution also combats additional contaminants including calcium, nickel, vanadium, sodium, and silicon,” Leach explained further.
Ketjen’s next generation SaFeGuard™ technology is currently available for use by refiners around the globe. Contact us or visit our website to learn more about how you can unlock the full potential of your FCC unit.
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