Innovative Ideas and News from Grace Refining Technologies
W. R. Grace & Co. experts demonstrate the value of doing business with Grace in Catalagram. From improved product performance to increased profitability, Grace's FCC catalysts and additives and ART's hydroprocessing catalysts and catalysts systems deliver significant value in today's challenging refining environment.
In This Issue
Introducing Fusion™ catalyst: The best of both worlds
The FUSION™ advanced matrix binding system deploys a combination of market leading Grace technologies for intrinsic bottoms cracking and metals trapping into a single catalyst particle. This unique characteristic reduces the diffusion path length compared to alternative catalyst systems or separate particle metals traps solutions. Improved diffusion of heavy feed components facilitates pre-cracking of large feed molecules, and combined with the latest generation of metal trapping technologies, delivers premium coke selective bottoms cracking.
RIVE® FCC CATALYST POWERD BY MOLECULAR HIGHWAY® ZEOLITE TECHNOLOGY
This breakthrough technology improves traditional zeolite catalysts through the introduction of highly interconnected channels of medium pore size, which enhance diffusion of feed molecules inside zeolite crystals, leading to higher value product yields, improved process efficiency and increased refinery profitability. Combined with Grace's market leading capabilities in FCC catalyst formulation and manufacturing, Rive Technology Inc. and W. R. Grace & Co. co-developed and commercialized the groundbreaking RIVE® FCC catalysts in the refinery industry.
RESIDUUM OIL HYDROCRACKING: CHEMISTRY AND CATALYSIS
Significant advances have been made in both understanding the hydrocracking chemistry of residuum oils and in the catalysis and catalytic systems required for deep conversion well above 90% of the vacuum residua. The hydrocracking of residuum oil fractions has been practiced for nearly six decades, evolving from simpler, single catalyst ebullated bed reactor systems capable of 65-70 wt.% vacuum bottoms conversion to the latest slurry hydrocracking systems that effectively push vacuum bottoms conversion well beyond 90 wt.% up to 97-98 wt.%. Deep conversion of residuum enables the production of ultra-low sulfur (ULS) fuels as well as feed preparation for petrochemicals production.
ROUTES TO MAXIMIZE FCC PROFITS DURING THE IMO 2020 PHASE IN
In most refineries, the FCC bottoms is a reasonably high sulfur stream (1wt%+), and the combination of the high sulfur and the suspended catalyst particulates create a specific challenge for marine fuel blending under IMO 2020. At the same time, the value of middle distillates, including FCC LCO, is pushing toward a relative maximum. Together, these forces line up to drive the incentive to upgrade FCC bottoms to an all-time high. Luckily, prior to the new IMO regulations, upgrading FCC bottoms to higher value products was often a strong economic driver on the FCC. With the onset of new marine regulations, this incentive is poised to become the most significant economic driver for even more FCCs globally.
A REVOLUTION IN THE LUBRICANT BASE OIL INDUSTRY
Over 25 years ago, in 1993, the first pound of ISODEWAXING® (IDW®) catalyst was placed in service, which launched a revolution in the lubricant base oil industry. Since then, continuous R&D to improve IDW® catalysts done by Chevron and ART has led to significant breakthroughs, launching new generations of IDW® catalyst. After many years of R&D, and a rigorous 13 months of continuous testing on six different feeds, ART's 5th generation IDW® catalyst was proven and ready to commercialize.
INCREASING CUSTOMER SUSTAINABILITY
Grace is proud that our products contribute to our customers' sustainability objectives, whether the products improve our customers' products or processes, enable our customers to reformulate their products to meet consumer demand, or help customers meet strict environmental standards. Approximately $0.3B of Grace's 2018 sales were generated by products that directly enable customers to meet environmental standards. Grace is pleased to announce the development of new FCC additive technology to further drive SOx emission reduction.
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