​​​Catalagram 124 - Fall 2019

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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.

​​​Catalagram 123 - Spring 2019

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MORE PROFIT FROM YOUR FCC? RIVE MAY BE YOUR SOLUTION

Since 2010, Rive has been commercializing Molecular Highway™ zeolites in FCC catalysts with W. R. Grace and Grace/Rive is currently supplying multiple FCC units around the world with the first, and only, use of ordered mesoporosity in FCC catalysts capable of providing a step change in value for many FCC operations.

INDUSTRY LEADERS WEIGH IN ON THE FUTURE OF REFINING

In October 2018, Grace convened a panel of refining industry experts to discuss present and future challenges to FCC operation as part of its FCC Technology Conference in Rotterdam in the Netherlands. More than 140 delegates, from 55 companies including refiners and other FCC shareholders attended the conference and participated in a broad technical program. That panel discussion is transcribed here.

GENERATING VALUE IN THE FCC THROUGH INNOVATIVE CATALYST TECHNOLOGIES AND TECHNICAL SERVICES

LUKOIL Neftochim Burgas Refinery JSC (Neftochim) commissioned an H-Oil Vacuum Residue Ebullating Bed Hydrocracker in 2015 that led to a significant deterioration of the FCC unit VGO feedstock quality. Consequently, a significant drop of conversion was observed that negatively affected FCC unit profitability. Grace and Neftochim went through the challenge successfully by means of a strong collaboration that included state of the art catalyst technology implementation together with a variety of tailored services, resulting in a gain of +1.6 wt.% conversion and 0.86 wt.% gasoline in the new more challenging scenario.

Q&A FROM THE 2018 AFPM OPERATIONS AND PROCESS TECHNOLOGY SUMMIT

Our experts address such questions as “Are there any operational parameters that can be manipulated to improve the operation of the slurry circuit and minimize fouling?” and “What is the range of activity for FCC catalysts in the FCCUs?”

​​​Catalagram 122 - Fall 2018

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FCC SOX REDUCTION ADDITIVES; IMPROVING WGS SCRUBBER ECONOMICS

FCC SOx reduction additives represent a CAPEX-free approach with lower OPEX costs, and provide refiners with a high degree of flexibility for controlling SOx emissions across a wide range of operational conditions.

A CATALYSTIC R​​​EMEMDY FOR ADVANCED UCO BLEED REDUCTION IN RECYCLE HYDROCRACKING OPERATIONS

A refinery’s flexibility and responsiveness to market dynamics and regulatory environments has a major impact on its competitive position. Tighter specifications on refinery process schemes combined with more robust catalyst systems affords more sustainably turning a larger portfolio of opportunity feedstocks into a product slate that is more in sync with the market dynamics.

IMPROVING OPERATING PROFITABILITY AT THE REFINERY WITH ACHIEVE® TECHNOLOGY

In this article, KMG Rompetrol and Grace provide an overview on how refineries can increase the profitability of their FCC operation by maximizing the production of propylene and iso-butylene using the latest FCC catalyst and additive technology. ACHIEVE® technology from Grace has contributed sustaining the refinery’s profitability, as well as improving its competitive position in the marketplace.

REDUCING NOX EMISSION FROM THE HELLENIC PETROLEUM FCC UNIT

As a result of the Industrial Emissions Directive (IED), the main EU instrument regulating pollutant emissions from industrial installations, many refiners in the EU are facing more stringent SOx and NOx emissions with additional emission reduction targets coming into effect in 2018. One such refinery is Hellenic Petroleum’s, Aspropyrgos Refinery in Greece who have successfully managed to reduce NOx emissions using Grace FCC additive technology.

NEWEST ADDITIONS TO SMART® CATALYST SYSTEM TECHNOLOGY ACHIEVE LONGER RUN LENGTHS THROUGH INCREASED ACTIVITY, IMPROVED STABILITY

ART Hydroprocessing’s DX® Catalyst Series has demonstrated superior performance in ULSD applications, exceeding expectations for many years and ART’s 425DX and 545DX catalysts continue to excel in middle distillate after worldwide acceptance. Responding to the need to balance feedstock flexibility, cycle length, and product flexibility, ART developed ICR 316 and 548DX to process tougher feeds, meet tighter specifications, improve product quality, and expand capacity with no additional capital costs.​

​​​Catalagram 121 - Spring 2018

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DRIVING HYDROCRACKER PRETREAT CATALYST DEVELOPMENT

In this article, our hydrocracking experts from Advanced Refining Technologies (ART), a joint venture with Chevron, cover state-of-the-art technologies to help refiners take advantage of opportunity crudes and meet ever more stringent environmental standards. 

ASK THE EXPERTS

This regular column features answers from Grace and ART experts in response to frequently asked questions or common scenarios. Michael Federspiel (Grace) and Lyle Schoellkopf (ART) provide insight into improving FCC unit and hydroprocessing operations based on questions from the AFPM Process Technology Summit in October 2017. ​​