Catalysts

Grace Catalagram®

Catalagram^® is the premiere publication covering Grace's catalysts technologies business. For more than 50 years, Catalagram^® has featured articles from our technical experts and strategic business partners that demonstrate the value of doing business with Grace. From improved unit performance to increased profitability, Grace's catalysts and catalysts systems have delivered—and continue to deliver—significant value to customers around the globe.

Past issues of Grace's Catalagram^® publication are located here for your convenience. To access the current issue of Catalagram^®, click here.

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 REMEMDY 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.

Catalagram 120 - Fall 2017

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DRIVING OCTANE IN AN ULTRA-LOW SULFUR GASOLINE MARKET

In this article we discuss octane fundamentals, the specifics of Tier 3 regulations and visit a number of refinery case studies and operating strategies for preserving octane, maximizing alkylation rates, and reducing sulfur to maintain regulatory compliance. Also, we illustrate the value in each operational or catalytic route available using an example of a 50kbpd refinery against recent U.S. economics.

MOTIVA UNLOCKS VALUE WITH AN INNOVATIVE CATALYST SOLUTION FROM RIVE AND GRACE

Through a unique collaborative effort between Motiva, Grace, and Rive Technology, an innovative catalyst solution incorporating Rive’s mesoporous zeolite was designed a trialed at a Motiva U.S. Gulf Coast refinery. Rive’s zeolite technology imparts a precise series of mesopores into Y zeolite framework, the primary active component of all FCC catalysts, which enhances diffusion of molecules into and out of the catalyst. Maximizing diffusion of feed into and products out of an FCC catalyst is critical to unlocking the full value potential on an FCC unit in which the riser residence time is only a few seconds. Read the full case study here.

UNDERSTANDING CATALYTIC SOLUTIONS FOR INCREASING MIDDLE DISTILLATE YIELDS

To take maximum advantage of domestic crude and opportunity feed sources, refiners are exploring ways to maximize their middle distillate production. In the process they are discovering issues not previously considered. Improvements in catalyst solutions and a detailed understanding of hydrotreater kinetics have provided avenues for significant advances. In this article, Advanced Refining Technologies (ART) explains the extensive pilot plant work done to better understand these potential options.

IMPROVING FCC UNIT PROFITABILITY

Close collaboration was key to helping Hellenic Petroleum S. A.’s (HELPE) Aspropyrgos refinery enhance FCC unit profitability. Read how HELPE made a series of improvements to debottleneck certain downstream units which resulted in higher capacity for propylene and LPG processing. Grace worked closely with the HELPE FCC team ahead of the revamp to prepare a catalysts formulation that would fit the increased challenges.

Catalagram 119 - Spring 2017

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CEPSA BOOSTS PROFITABILITY THROUGH FCC CATALYST SELECTION

Grace's customized FCC catalyst and dedicated and proactive technical support, enabled Cepsa's Gibraltar refinery to maximize propylene and isobutylene yields, enhance LPF production, maintain gasoline yield, improve bottoms upgrading, and process heavier feed.

ART FCC PRETREAT CATALYSTS PROVIDE SUPERIOR TECHNOLOGY, PERFORMANCE

Advanced Refining Technologies (ART), Grace's joint venture with Chevron, steps up to meet the challenges of clean fuels regulations with its newest ApART® Catalyst System ultra high activity FCC pretreat catalysts: 586 DX® and 486 DX®.

ADDITIVES REDUCE SULFUR CONTENT IN FCC NAPHTHA

A case study shows demonstrates that the use of catalytic additives to reduce sulfur in gasoline is a viable alternative for the refining industry challenged to produce a greater volume of fuel at the highest quality standards.

Q & A FROM AFPM CAT CRACKER SEMINAR

An in-depth look into improving FCC unit operation from Grace Americas FCC Technical Service Leader Ann Beniot.


		Catalagram 118 - Summer 2016/Fall 2016 Download COMBATING THE NEGATIVE EFFECTS OF IRON IN AN FCC UNIT With a combination of operating strategies and FCC catalyst optimization, a Philadelphia refinery maintains profitability in a challenging environment. IMPROVED CATALYST TECHNOLOGIES MANAGE REFINER’S NEED FOR INCREASED MIDDLE DISTILLATE YIELDS Proper design and selection of a catalyst system for hydroprocessing is critical to increasing diesel yield. COMMERCIAL SUCCESS OF ACHIEVE® 400 FCC CATALYST AT A US REFINER A case study shows how a catalyst change led to increased profitability. GSR® – THE ONLY PROVEN FCC CATALYSTS AND ADDITIVES FOR SULFUR REDUCTION An in-depth look at how Grace’s innovative technologies create economic opportunities and options for refiners.

Catalagram 118 - Summer 2016/Fall 2016

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COMBATING THE NEGATIVE EFFECTS OF IRON IN AN FCC UNIT

With a combination of operating strategies and FCC catalyst optimization, a Philadelphia refinery maintains profitability in a challenging environment.

IMPROVED CATALYST TECHNOLOGIES MANAGE REFINER’S NEED FOR INCREASED MIDDLE DISTILLATE YIELDS

Proper design and selection of a catalyst system for hydroprocessing is critical to increasing diesel yield.

COMMERCIAL SUCCESS OF ACHIEVE® 400 FCC CATALYST AT A US REFINER

A case study shows how a catalyst change led to increased profitability.

GSR® – THE ONLY PROVEN FCC CATALYSTS AND ADDITIVES FOR SULFUR REDUCTION

An in-depth look at how Grace’s innovative technologies create economic opportunities and options for refiners.

Catalagram 117 - Fall 2015/Winter 2016

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PARTNERS IN CHANGE

A message from Al Beninati

GRACE IN THE NEWS

Catch up on the latest happenings within Grace Catalysts Technologies

GOT JET?

Maximize hydrocracker jet fuel production with ART catalysts

THE FASTEST ROUTETO HIGHER OCTANES

FCC gasoline octane can be increased in several ways. What is the most effective for you?

CATALYST BEST PRACTICES –LESSONS FROM RESID FCC UNITS IN THE MIDDLE EAST

Serving the largest FCCs in the world with the right performance and logistics capabilities

ASK THE EXPERTS

Grace experts answer questions from the 2015 AFPM Q&A session

Catalagram 116 - Spring 2015

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AL BENINATI Q&A

Grace Catalysts Technologies President answers questions about how Grace is responding to market trends

DISTINCTION IN SAFETY

Grace Lake Charles catalyst manufacturing facility receives highest OSHA rating

GENERATING VALUE WITH FCC CATALYST INNOVATION AT PLACID REFINING

Refiner increases production with high-activity MIDAS® Gold FCC catalyst

ACHIEVING STATE-OF-THE-ART FCC CATALYST SOLUTIONS

The new ACHIEVE® series offers tailor-made formulations

LEADING THE WAY WITH FIXED BED RESID HYDROPROCESSING TECHNOLOGIES

Helping refiners take advantage of heavier feeds

UNDERSTANDING THE POTENTIAL FOR FCC FEED TO GENERATE VALUABLE PRODUCTS

A look at how to estimate product yields to achieve the maximum potential in the FCCU

CATALYST ADVANCES TO ENABLE CLEARER POLYPROPYLENE

Lighter, faster, cleaner, and clearer with CONSISTA® catalysts

		Catalagram 115 - Fall 2014 Download ADVANCES IN PROPYLENE MAXIMIZATION FROM THE FCC UNIT A new method to characterize ZSM-5 based materials is introduced ADDRESSING POLYPROPYLENE DEMAND Leading the way with UNIPOL® Polypropylene Process Technology AFPM Q&A RESPONSES Grace FCC and ART HPC experts address market trends and answer questions submitted to the 2014 AFPM Q&A and Technology Forum held in Denver, Colorado REDUCING SOx EMISSIONS AT BP CASTELLON USING FCC ADDITIVES FCC additives offer an attractive alternative to reduce SOx emissions IMPROVING SAFETY, RELIABILITY AND PROFITABILITY AT THE ORPIC SOHAR REFINERY Grace's catalyst management solutions stand up to the challenge at the Sohar RFCC unit

		Catalagram 114 - Spring 2014 Download Full Edition Individual Articles: Processing Tight Oils in FCC: Issues, Opportunities and Flexible Catalytic Solutions Tight Oil Distillate in ULSD Production, What To Expect? Two Companies Joined to Develop a Catalytic Solution for Bottoms Upgrading to Diesel in the FCC Unit Meeting Tier 3 Gasoline Sulfur Regulations

		Catalagram 113 - Spring 2013 Download Full Edition Individual Articles: Flexible Pilot Plant Technology for Evaluation of Unconventional Feedstocks and Processes Rive Molecular HighwayTM Catalyst Delivers Over $2.50/bbl Uplift at Alon's Big Spring, Texas Refinery Custom Catalyst Systems for Higher Yields of Diesel

		Catalagram 112 - Fall 2012 Download Full Edition Individual Articles: Enhanced Bottoms Cracking and Process Flexibility with MIDAS® FCC Catalyst REMEDY® Catalyst Delivers Performance at Reduced Rare-Earth Levels Stabilize Catalyst Circulation with FLOWMOTION^®FCC Fluidization Additive Predict FCCU Performance with Laboratory Testing Answers to the 2012 AFPM Q&A Questions

		Catalagram 111 - Spring 2012 Download Full Edition Individual Articles: Alternatives to Rare Earth - Commercial Evaluation of REpLaCeR® FCC Catalysts at Montana Refining Company Maximize Distillate Yield to Meet Growing Market Demand Improve Wet Gas Scrubber Economics with Super DESOX® Additives Improve Contaminant Metals Flushing with TITAN™ Maximize Yields of High Quality Diesel

		Catalagram 110 - Fall 2011 Download Full Edition Individual Articles: Optimizing FCC Operations in a High Rare-Earth Cost World: Commercial Update on Grace Davison's Low and Zero Rare-Earth FCC Catalysts Commercial Demonstration of Resid Ultra Catalyst in a Resid Processing Application at S-Oil Corporation Two Great Organizations United by a Catalyst FCC Catalyst Age Distribution Optimization Leads to Improved Profitability 2011 NPRA Q&A Answers

		Catalagram 109 - Spring 2011 Download Full Edition Individual Articles: Jointly Developed FCC Catalysts with Novel Mesoporous Zeolite Deliver Higher Yields and Economic Value to Refiners The Development of Rare-Earth Free FCC Catalysts A New Generation of Super DESOX® Additive ResidUltraTM: Low RE Catalyst Technology for Resid Processing Applications Worldwide FCC Equilibrium Catalyst Trends GDNOXTM 1 Additive - Grace Davison's Next Generation NOx Reduction Additive Improving FCC Economics with Light Olefins Additives Higher Profits from Higher Sulfur Grace Davison's EZTM Loader Additive Injection System Balancing the Need for Low Sulfur FCC Products and Increasing FCC LCO Yields by Applying Advanced Technology for Cat Feed Hydrotreating

		Catalagram 108 - Fall 2010 Download Full Edition Individual Articles: Alcyon™: New Catalyst Design for Maximum Activity and Conversion Reducing Sulfur Oxide Emissions from the FCC Unit OlefinsUltra® HZ Technology Improves Propylene Yields The Role of the Rare Earth Elements in Fluid Catalytic Cracking Answers to the 2010 NPRA Q&A FCC Questions Low NOx FCC Promoter Optimization at CITGO Petroleum Corporation's Lake Charles Refinery

		Catalagram 107 - Spring 2010 Download Full Edition Individual Articles: Grace's GENESIS® Catalyst Systems Provide Refiners the Flexibility to Capture Economic Opportunities Development of Next Generation Low NOx Combustion Promoters Based on New Mechanistic Insights Distillate Pool Maximization by Additional LCO Hydroprocessing Salt Deposition in FCC Gas Concentration Units

		Catalagram 106 - Fall 2009 Download Full Edition Individual Articles: Coke Selectivity Fundamentals Trouble-Shooting FCC Standpipe Flow Problems IMPACT®: A Breakthrough Technology for Resid Processing Use Hydrogen in Coke Number to Determine Coke Make Accuracy Clean Fuels: An Opportunity for Profitability Using Gasoline Sulfur Reduction Technology

		Catalagram 105 - Spring 2009 Download Full Edition Individual Articles: Recycle Strategies and MIDAS®-300 for Maximizing FCC Light Cycle Oil Distillate Pool Maximization by Exploiting the Use of Opportunity Feedstocks Such as LCO and Syncrude Characterization and Catalytic Cracking of Synthetic Crude Feedstocks Factors Influencing ULSD Product Color

		Catalagram 104 - Fall 2008 Download Full Edition Individual Articles: Maximizing FCC Light Cycle Oil Operating Strategies: Introducing MIDAS®-300 Catalyst for Increased Selectivity Maximizing ULSD Unit Performance when Processing LCO and Other Previously Processed Feeds Grace Issues New Shipping Guidlines for Hydrocarbon Samples Answers to Questions from the 2008 NPRA Q&A Session - FCC Section

		Catalagram 103 - Spring 2008 Download Full Edition Individual Articles: New Opportunities for Co-Processing Renewable Feeds in Refinery Processes GENESISTM Catalyst Commercial Update Effect of Hydrocarbon Partial Pressure on Propylene Production in the FCC Meet Clean Fuels Challenges with Advanced Refining Technologies Newest ULSD Catalysts – ART 420DX™ Successful Implementation of State-of-the-Art ULSD/Dewaxing Technology at Irving Oil, Saint John, NB

		Catalagram 102 - Fall 2007 Download Full Edition Individual Articles: The GENESISTM Catalyst System GSR Products Maintain Excellent Performance When Used with Olefins Additives Worldwide FCC Equilibrium Catalyst Trends: A Ten-Year Review The Effects of Treat Gas H2 Purity on ULSD Catalyst Performance Catalytic FCC Gasoline Sulfur Reduction: Mechanism of Sulfur Reduction