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SUPERIOR COKE SELECTIVITY AND BOTTOMS CRACKING FROM A NOVEL SINGLE PARTICLE


One of the keys to optimal FCC catalyst performance is striking the right balance between zeolite and matrix, both in terms of selectivity and activity. Historically, catalysts systems containing a high matrix input to maximize conversion of bottoms and a high zeolite input to impart favorable coke and gas selectivities, has been known to outperform individual catalyst offerings. Grace has successfully commercialized these types of catalyst systems in more than 100 refineries worldwide, and they continue to form a valuable segment of our industry leading catalyst portfolio today.

Until now, however, the mechanism to unlock premium coke to bottoms performance has been achieved through the combination of two complimentary catalyst components with individual matrix technologies. Through worldclass R&D, as well as manufacturing and processing advances, Grace has developed a catalyst solution, FUSION™ catalyst, which incorporates a differentiated advanced matrix binding system in a single catalyst particle. By reducing the proximate distance between multiple Grace technologies into the span of a single particle, the synergistic effects are magnified in FUSION™ catalyst to deliver premium catalyst performance for moderate and heavy metals applications.

​THE FUSION™ CATALYST ADVANTAGE​

  • Improved FCCU product selectivity

  • Increased metals tolerance (vanadium & nickel) and bottoms conversion

  • Optimized porosity for increased catalytic performance.


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Conversion of heavier feedstocks with high contaminant metals is critical to maximizing FCCU profitability. Increasing the yields of the desired streams such as cracked naphtha, middle distillates and light olefins remains an important target to generate an economic uplift for refiners. However, processing difficult and more cost-attractive feedstocks to produce high-value products remains a technical challenge due to limitations such as wet gas compressor and air blower capacity. With FUSION™ catalyst, Grace continues to innovate to tackle the pressures faced by the refining industry, to allow the profitable processing of ever changing and more challenging feedstocks around the globe.