Industrial Application of MacroCat-201S Catalyst with Low Steam–Oil Ratio in Large-Scale Styrene Unit

Styrene production primarily relies on ethylbenzene dehydrogenation catalysts, with increasing performance demands as styrene units scale up. This paper presents the industrial application of the MacroCat-201S ethylbenzene dehydrogenation catalyst at the 350,000 tons/year styrene plant of Liaoning Bora LyondellBasell Petrochemical Co., Ltd. The catalyst, primarily composed of potassium ferrate, demonstrates excellent thermal stability and mechanical strength, ensuring long-term stable operation under low steam–oil ratios (1.0). Over a 36-month application period, the MacroCat-201S catalyst maintained high conversion rates and selectivity, with minimal catalyst deactivation. It also showed good crush resistance, and the reactor pressure drop remained low, indicating its potential for long-term efficient operation in styrene production. This paper further examines the influence of process parameters such as the steam–oil ratio and reaction temperature on catalyst performance and suggests strategies for optimizing catalyst usage in industrial applications. This study concludes that the MacroCat-201S catalyst significantly improves the reaction efficiency, reduces energy consumption, and shows promising potential for industrial use.