Module 16  ·  Process · Maintenance

Catalyst & Chemical Inventory

Tracks catalyst inventory, activity decline, projected end-of-run, chemical consumption, and cost vs. budget. Generates procurement alerts and EOC forecasts.

Module 16 · Overview

Catalyst & Chemical Inventory

Catalyst & Chemical Inventory tracks the controllable OpEx that nobody tracks well today. Catalyst inventory and activity decline, projected end-of-run for FCC, reformer, and hydrotreater units, plus chemical consumption (caustic, amine, inhibitors) — all with cost vs. budget reporting and procurement alerts. Connects consumption to financial impact for the engineers who own these programs.

Why It Wins

Catalyst and chemical costs are a major controllable OpEx line ($5M–$30M/yr in a medium refinery). No one tracks this well today. Process engineers who manage catalyst programs will pay for a dedicated tool that connects consumption rates to financial impact.

Built For
Process Eng.Maintenance
Capabilities

Full Capability Set

Every capability included in Catalyst & Chemical Inventory.

Catalyst Tracking
Catalyst inventory by unitActivity decline trackingEnd-of-run (EOR) forecastingEOC (end-of-cycle) projectionFCC catalyst circulationReformer regeneration trackingHydrotreater bed lifeCatalyst replacement scheduling
Chemical Consumption
Caustic consumptionAmine consumption (MEA, DEA, MDEA)Corrosion inhibitor trackingAnti-foulant trackingDemulsifier usageAntifoam usageWash-water trackingSpecialty chemical inventory
Cost & Budget
Cost vs. budget by unitAnnualized run-ratePer-barrel cost allocationCatalyst depreciationBudget variance analysisVendor performance trackingTotal catalyst & chemical OpExConservation opportunities
Procurement & Forecasting
Procurement alertsEOC procurement timingLead-time-aware orderingStrategic stock managementMulti-vendor RFP supportQuality acceptance trackingSpent catalyst disposalRegulatory compliance
Use Cases

Catalyst & Chemical Inventory in Action

Scenario
FCC catalyst end-of-cycle planning
The FCC catalyst is approaching activity floor. The tool projects EOC, calculates the right procurement timing given lead time, and flags the budget impact. Procurement gets a structured RFP package.
Scenario
Annual chemical OpEx review
The plant manager reviews the year's controllable chemical spend. The dashboard shows where consumption is trending up, which vendors are performing, and where conservation projects could yield savings.
Scenario
Hydrotreater bed life forecasting
A hydrotreater is being pushed harder this year. The tool tracks the activity decline, forecasts EOR shifted by 4 months, and feeds the projection into TAR Scheduler for the next planned outage.

See Catalyst & Chemical Inventory on Your Refinery

Request a personalized demo. We will walk through Catalyst & Chemical Inventory on your refinery's actual configuration.

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