ASTM D5757-22

Standard Test Method for Determination of Attrition of FCC Catalysts by Air Jets

SIGNIFICANCE AND USE
5.1 This test method is intended to provide information concerning the ability of a powdered catalyst to resist particle size reduction during use in a fluidized environment.  
5.2 This test method is suitable for specification acceptance, manufacturing control, and research and development purposes.
SCOPE
1.1 This test method covers the determination of the relative attrition characteristics of FCC catalysts by means of air jet attrition. Other fine powder catalysts can be analyzed by this test method, but the precision of this test method has been determined only for FCC catalysts. It is applicable to spherically or irregularly shaped particles which range in size between 10 and 180 μm, have skeletal densities between 2.4 and 3.0 g/cm3 (2400 and 3000 kg/m3) (see IEEE/ASTM SI-10) and are insoluble in water. Particles less than 20 μm are considered fines. (See Terminology D3766.)  
1.2 Units—The values stated in SI units are to be regarded as standard. No other units of measurement are included in this standard.  
1.3 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety, health, and environmental practices and determine the applicability of regulatory limitations prior to use.  
1.4 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.

General Information

• Status: Published
• Publication Date: 30-Sep-2022
• ICS: 71.040.30 - Chemical reagents
• Technical Committee: D32 - Catalysts
• Drafting Committee: D32.02 - Physical-Mechanical Properties

Relations

• Refers: ASTM D3766-24a - Standard Terminology Relating to Catalysts and Catalysis
• Effective Date: 01-Feb-2024
• Refers: ASTM D3766-24 - Standard Terminology Relating to Catalysts and Catalysis
• Effective Date: 01-Jan-2024
• Refers: ASTM E456-13a(2022)e1 - Standard Terminology Relating to Quality and Statistics
• Effective Date: 01-Apr-2022
• Refers: ASTM D3766-08(2018) - Standard Terminology Relating to Catalysts and Catalysis
• Effective Date: 01-Nov-2018
• Refers: ASTM E456-13A(2017)e3 - Standard Terminology Relating to Quality and Statistics
• Effective Date: 01-Oct-2017
• Refers: ASTM E456-13A(2017)e1 - Standard Terminology Relating to Quality and Statistics
• Effective Date: 01-Oct-2017
• Refers: ASTM E177-14 - Standard Practice for Use of the Terms Precision and Bias in ASTM Test Methods
• Effective Date: 01-May-2014
• Refers: ASTM E456-13ae3 - Standard Terminology Relating to Quality and Statistics
• Effective Date: 15-Nov-2013
• Refers: ASTM E456-13a - Standard Terminology Relating to Quality and Statistics
• Effective Date: 15-Nov-2013
• Refers: ASTM E456-13ae1 - Standard Terminology Relating to Quality and Statistics
• Effective Date: 15-Nov-2013
• Refers: ASTM E456-13ae2 - Standard Terminology Relating to Quality and Statistics
• Effective Date: 15-Nov-2013
• Refers: ASTM E456-13 - Standard Terminology Relating to Quality and Statistics
• Effective Date: 15-Aug-2013
• Refers: ASTM E177-13 - Standard Practice for Use of the Terms Precision and Bias in ASTM Test Methods
• Effective Date: 01-May-2013
• Refers: ASTM E691-13 - Standard Practice for Conducting an Interlaboratory Study to Determine the Precision of a Test Method
• Effective Date: 01-May-2013
• Refers: ASTM D3766-08(2013) - Standard Terminology Relating to Catalysts and Catalysis
• Effective Date: 01-Mar-2013

Overview

ASTM D5757-22: Standard Test Method for Determination of Attrition of FCC Catalysts by Air Jets provides a standardized procedure for evaluating the resistance of fluid catalytic cracking (FCC) catalysts to attrition when subjected to air jets. This method measures the tendency of a powdered catalyst to break down into smaller particles (fines) during use in a fluidized environment, an essential property for ensuring catalyst performance and operational stability in refining and chemical processing industries.

Developed by ASTM International, this standard enables manufacturers, researchers, and quality control laboratories to assess catalyst durability consistently, supporting product specification, process optimization, and research and development.

Key Topics

• Attrition Resistance: The ability of FCC catalysts to maintain particle size under fluidized conditions, critical for minimizing operational issues like pressure drop and loss of catalyst activity.
• Test Methodology: Includes humification of catalyst samples, exposure to air jets in specialized apparatus, and the collection of fines through elutriation. The Air Jet Index (AJI) is calculated based on the mass of fines collected after a defined period, typically 5 hours.
• Applicability: While primarily validated for FCC catalysts, the method also applies to other powdered catalysts with spherical or irregular shapes, particle sizes from 10 to 180 μm, and skeletal densities between 2.4 and 3.0 g/cm³, provided they are insoluble in water.
• Precision & Reporting: The standard outlines statistical methods for repeatability and reproducibility, providing guidance on evaluating test consistency within and between laboratories.

Applications

Quality and Process Control

• Specification Acceptance: Ensures catalyst suppliers meet specified attrition resistance requirements.
• Manufacturing Control: Supports batch consistency and prompts process adjustments if product attrition characteristics change.
• Research and Development: Assesses the impact of formulation or processing changes on catalyst durability.

Industrial Relevance

• Petrochemical & Refining Operations: Maintaining catalyst integrity reduces operational downtime, minimizes equipment fouling, and manages environmental emissions related to catalyst loss.
• Catalyst Manufacturing: Facilitates the optimization of production processes to yield particles with optimal hardness and resistance to attrition, contributing to the development of higher-performance materials.

Extended Usability

Although precision has been verified primarily for FCC catalysts, the test method is broadly applicable to other industrial catalysts that function in a fluidized bed, provided their physical properties fall within the specified range.

Related Standards

The following ASTM and allied standards are referenced or relevant for users of ASTM D5757-22 interested in catalyst attrition testing and quality assurance:

• ASTM D3766 - Terminology Relating to Catalysts and Catalysis
• ASTM E105 - Guide for Probability Sampling of Materials
• ASTM E177 - Practice for Use of the Terms Precision and Bias in ASTM Test Methods
• ASTM E456 - Terminology Relating to Quality and Statistics
• ASTM E691 - Practice for Conducting an Interlaboratory Study to Determine the Precision of a Test Method
• IEEE/ASTM SI-10 - Standard for Use of the International System of Units (SI)

Practical Value

Implementing ASTM D5757-22 ensures objective, repeatable assessment of FCC catalyst attrition, allowing manufacturers and end-users to:

• Reduce operating costs by minimizing catalyst loss and equipment wear.
• Improve operational reliability and safety in fluidized reactor systems.
• Make data-driven decisions in catalyst development and selection.

This test method is internationally recognized and developed in accordance with WTO technical standards, supporting compliance and trade in global refining, chemical, and catalyst manufacturing markets.

Keywords: FCC catalysts, attrition resistance, air jet test, powdered catalysts, catalyst quality control, ASTM D5757-22, fines collection, catalyst testing standard.

Standards Content (Sample)

This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the
Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
Designation: D5757 − 22
Standard Test Method for
Determination of Attrition of FCC Catalysts by Air Jets
This standard is issued under the fixed designation D5757; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
1. Scope E691 Practice for Conducting an Interlaboratory Study to
Determine the Precision of a Test Method
1.1 This test method covers the determination of the relative
IEEE/ASTM SI-10 Standard for Use of the International
attrition characteristics of FCC catalysts by means of air jet
System of Units (SI): The Modern Metric System
attrition. Other fine powder catalysts can be analyzed by this
test method, but the precision of this test method has been
3. Terminology
determined only for FCC catalysts. It is applicable to spheri-
3.1 Definitions of Terms Specific to This Standard:
cally or irregularly shaped particles which range in size
between 10 and 180 µm, have skeletal densities between 2.4 3.1.1 Air Jet Index (AJI), n—a unitless value numerically
3 3
equal to the percent attrition loss at 5 h.
and 3.0 g⁄cm (2400 and 3000 kg⁄m ) (see IEEE/ASTM SI-
10) and are insoluble in water. Particles less than 20 µm are
4. Summary of Test Method
considered fines. (See Terminology D3766.)
4.1 A sample of dried powder is humidified and attrited by
1.2 Units—The values stated in SI units are to be regarded
means of three high velocity jets of humidified air. The fines
as standard. No other units of measurement are included in this
are continuously removed from the attrition zone by elutriation
standard.
into a fines collection assembly.
1.3 This standard does not purport to address all of the
safety concerns, if any, associated with its use. It is the 4.2 The AJI is calculated from the elutriated fines to give a
relative estimate of the attrition resistance of the powdered
responsibility of the user of this standard to establish appro-
catalyst as may be observed in commercial use.
priate safety, health, and environmental practices and deter-
mine the applicability of regulatory limitations prior to use.
5. Significance and Use
1.4 This international standard was developed in accor-
dance with internationally recognized principles on standard-
5.1 This test method is intended to provide information
ization established in the Decision on Principles for the
concerning the ability of a powdered catalyst to resist particle
Development of International Standards, Guides and Recom-
size reduction during use in a fluidized environment.
mendations issued by the World Trade Organization Technical
5.2 This test method is suitable for specification acceptance,
Barriers to Trade (TBT) Committee.
manufacturing control, and research and development pur-
poses.
2. Referenced Documents
2.1 ASTM Standards:
6. Apparatus
D3766 Terminology Relating to Catalysts and Catalysis
6.1 The air jet attrition system consists of the following:
E105 Guide for Probability Sampling of Materials
6.1.1 Attrition Tube, a stainless steel tube 710 mm long with
E177 Practice for Use of the Terms Precision and Bias in
a 35 mm inside diameter.
ASTM Test Methods
E456 Terminology Relating to Quality and Statistics NOTE 1—NPS 1 ⁄4 in. pipe, Schedule 40 has the appropriate inside
diameter.
6.1.2 Three 2 mm Long Drilled Sapphire Square Edged
This test method is under the jurisdiction of ASTM Committee D32 on
Nozzles, precision drilled 0.381 6 0.005 mm in diameter.They
Catalysts and is the direct responsibility of Subcommittee D32.02 on Physical-
are mounted equidistant from each other, 10 mm from center
Mechanical Properties.
and flush with the top surface in a circular orifice plate 6.4 mm
Current edition approved Oct. 1, 2022. Published October 2022. Originally
thick. The plate is designed to be attached to the bottom of the
approved in 1995. Last previous edition approved in 2017 as D5757 – 11(2017).
DOI: 10.1520/D5757-22.
vertical attrition tube within an air delivery manifold.
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
6.1.3 Settling Chamber, a 300 mm long cylinder with a
contact ASTM Customer Service at [e-mail]. For Annual Book of ASTM
110 mm inside diameter and with conical ends reducing to
Standards volume information, refer to the standard’s Document Summary page on
the ASTM website. 30 mm inside diameter. The upper cone is approximately
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
D5757 − 22
100 mm long and the lower cone is approximately 230 mm 7.4.3 Mix 45 g of the dried and cooled material thoroughly
long. The chamber is mounted to the top of the attrition tube. with 5 g of demineralized water ensuring that the water is well
6.1.4 Fines Collection Assembly, made up of a 250 mL dispersed and that there are no lumps of material present.
filtering flask, an extraction thimble connected to the side arms 7.4.4 Allow the sample to stand over a saturated calcium
of the flask, and a 200 by 13 mm diameter metal tubing bent to chloride solution in a humidifier for 1 h.
anangleof125°connectingthetopoftheflasktothetopofthe
8. Preparation of Apparatus
settling chamber.
8.1 Thoroughly clean any residual material from the appa-
NOTE 2—The flask may be eliminated and the thimble connected
ratus by tapping it loose and blowing or vacuuming the dust.
directly to the tubing if the attrition is expected to be low enough to avoid
Reassemble the system except for the fines collection assem-
clogging the thimble and creating a backpressure in the settling chamber.
bly.
6.1.5 Rubber Couplers and Seals, appropriately sized to
8.2 Turn on the air supply and adjust the relative humidity
ensure tight and leak free connections of the system.
of the air exiting the settling chamber to a range of 30 to 40 %.
6.2 Air Supply Source, controlled and capable of maintain-
ing an air flow rate of 10.00 L⁄min stable to 0.05 L⁄min at a 8.3 Connect the inlet of the wet test gas meter to the top of
thesettlingchamberandadjustthehumidifiedairflowto10.00
pressure up to 200 kPa. The air must be at a relative humidity
of 30 to 40 % to minimize electrostatic effects. 6 0.05 L⁄min at standard temperature and pressure (STP)
(273.15 K and 101.325 kPa). The back pressure should be in
NOTE3—Theairmaybebubbledthrougha0.25 mcolumnofdeionized
the range of 130 to 180 kPa; if it is not, check that the air jet
water
...

This document is not an ASTM standard and is intended only to provide the user of an ASTM standard an indication of what changes have been made to the previous version. Because
it may not be technically possible to adequately depict all changes accurately, ASTM recommends that users consult prior editions as appropriate. In all cases only the current version
of the standard as published by ASTM is to be considered the official document.
Designation: D5757 − 11 (Reapproved 2017) D5757 − 22
Standard Test Method for
Determination of Attrition of FCC Catalysts by Air Jets
This standard is issued under the fixed designation D5757; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
1. Scope
1.1 This test method covers the determination of the relative attrition characteristics of FCC catalysts by means of air jet attrition.
Other fine powder catalysts can be analyzed by this test method, but the precision of this test method has been determined only
for FCC catalysts. It is applicable to spherically or irregularly shaped particles which range in size between 10 and 180 μm,
3 3
180 μm, have skeletal densities between 2.4 and 3.0 3.0 g g/cm⁄cm (2400 and 3000 kg ⁄m ) (see IEEE/ASTM SI-10) and are
insoluble in water. Particles less than 20 μm are considered fines. (See Terminology D3766.)
1.2 Units—The values stated in SI units are to be regarded as standard. No other units of measurement are included in this
standard.
1.3 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility
of the user of this standard to establish appropriate safety safety, health, and healthenvironmental practices and determine the
applicability of regulatory limitations prior to use.
1.4 This international standard was developed in accordance with internationally recognized principles on standardization
established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued
by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
2. Referenced Documents
2.1 ASTM Standards:
D3766 Terminology Relating to Catalysts and Catalysis
E105 Guide for Probability Sampling of Materials
E177 Practice for Use of the Terms Precision and Bias in ASTM Test Methods
E456 Terminology Relating to Quality and Statistics
E691 Practice for Conducting an Interlaboratory Study to Determine the Precision of a Test Method
IEEE/ASTM SI-10 Standard for Use of the International System of Units (SI): The Modern Metric System
3. Terminology
3.1 Definitions of Terms Specific to This Standard:
3.1.1 Air Jet Index (AJI)—(AJI), n—a unitless value numerically equal to the percent attrition loss at 5 h.5 h.
This test method is under the jurisdiction of ASTM Committee D32 on Catalysts and is the direct responsibility of Subcommittee D32.02 on Physical-Mechanical
Properties.
Current edition approved Feb. 1, 2017Oct. 1, 2022. Published February 2017October 2022. Originally approved in 1995. Last previous edition approved in 20112017 as
D5757D5757 – 11–11.(2017). DOI: 10.1520/D5757-11R17.10.1520/D5757-22.
For referenced ASTM standards, visit the ASTM website, www.astm.org, or contact ASTM Customer Service at [e-mail]. For Annual Book of ASTM Standards
volume information, refer to the standard’s Document Summary page on the ASTM website.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
D5757 − 22
4. Summary of Test Method
4.1 A sample of dried powder is humidified and attrited by means of three high velocity jets of humidified air. The fines are
continuously removed from the attrition zone by elutriation into a fines collection assembly.
4.2 The AJI is calculated from the elutriated fines to give a relative estimate of the attrition resistance of the powdered catalyst
as may be observed in commercial use.
5. Significance and Use
5.1 This test method is intended to provide information concerning the ability of a powdered catalyst to resist particle size
reduction during use in a fluidized environment.
5.2 This test method is suitable for specification acceptance, manufacturing control, and research and development purposes.
6. Apparatus
6.1 The air jet attrition system consists of the following:
6.1.1 Attrition Tube, a stainless steel tube 710-mm710 mm long with a 35-mm35 mm inside diameter.
NOTE 1—NPS 1 ⁄4-in. in. pipe, Schedule 40 has the appropriate inside diameter.
6.1.2 Three 2-mm2 mm Long Drilled Sapphire Square Edged Nozzles, precision drilled 0.381 6 0.005 mm 0.005 mm in diameter.
They are mounted equidistant from each other, 10 mm from center and flush with the top surface in a circular orifice plate
6.4-mm6.4 mm thick. The plate is designed to be attached to the bottom of the vertical attrition tube within an air delivery
manifold.
6.1.3 Settling Chamber, a 300-mm300 mm long cylinder with a 110-mm110 mm inside diameter and with conical ends reducing
to 30-mm30 mm inside diameter. The upper cone is approximately 100-mm100 mm long and the lower cone is approximately
230-mm230 mm long. The chamber is mounted to the top of the attrition tube.
6.1.4 Fines Collection Assembly, made up of a 250-mL250 mL filtering flask, an extraction thimble connected to the side arms of
the flask, and a 200 by 13-mm13 mm diameter metal tubing bent to an angle of 125° connecting the top of the flask to the top of
the settling chamber.
NOTE 2—The flask may be eliminated and the thimble connected directly to the tubing if the attrition is expected to be low enough to avoid clogging
the thimble and creating a backpressure in the settling chamber.
6.1.5 Rubber Couplers and Seals, appropriately sized to ensure tight and leak free connections of the system.
6.2 Air Supply Source, controlled and capable of maintaining an air flow rate of 10.0010.00 L L/min ⁄min stable to 0.050.05 L
L/min ⁄min at a pressure up to 200 kPa. 200 kPa. The air must be at a relative humidity of 30 to 40 % to minimize electrostatic
effects.
NOTE 3—The air may be bubbled through a 0.25-m0.25 m column of deionized water at ambient temperature to obtain the required humidity.
6.3 Diaphragm-Type Test Meter (dry test meter)(Dry Test Meter) or Liquid-Sealed Rotating Drum Meter (wet test meter),(Wet Test
Meter), minimum capacity of 3030 L L/min ⁄min and maximum scale subdivision of 0.1 L. Alternately, an electric L or electronic
mass flow controllercontrollers may be used.
6.4 Balance, 400-g400 g capacity open pan with 0.01-g0.01 g sensitivity.
6.5 Desiccator, with a desiccant grade molecular sieve such as 4A.
D5757 − 22
6.6 Muffle Furnace.
6.7 Relative Humidity Gage.
7. Sampling
7.1 Obtain a representative sample of approximately 65 g of material from larger composites by riffling or splitting with in
accordance with subsection 5.12 of STP 447A or some other suitable means with the aim of obtaining a sample that represents
the size distribution of the larger composite. The analyst should also consult Guide E105 to help develop a sampling plan.
7.2 Gently screen the
...