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Value Delivered

​​At Grace, value is all about our customers' financial success. Our world-class technical service and catalyst solutions, developed collaboratively with our customers, provide more than just technology and performance. They are designed to increase each customer's bottom line—by improving yields, increasing throughput or reliability, or solving a problem within the FCC, hydroprocessing or polyolefin unit. Our goal is not just to sell good catalysts; our goal is to strengthen our customers' businesses by providing exceptional financial return on their investment (and faith) in Grace's talent and technology.​

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​Improving FCC Unit Profitability​

​Multiple Approaches for
Improving Octane​​​​​​​​

​Innovative Catalyst Solution Unlocks FCC Value

Close collaboration was key to helping Hellenic Petroleum S.A.'s (HELPE) Aspropyrgos refinery enhance FCC unit profitability. Aspropyrgos refinery's FCC unit is an Exxon FlexiCrackeR® design, aiming at propylene production and minimum bottoms yield. To enhance profitability, HELPE made a series of improvements to debottleneck certain downstream units. Grace provided an enhanced catalyst system using MIDAS® catalyst and OlefinesUltra® MZ additive technologies. Clear target setting from the HELPE FCC team, as well as the reliability of the data provided aided in the reformulation, while Grace worked to ensure a smooth transition to the new catalyst system. The estimated improvement in the unit's profitability via the new technology amounts to at least 0.60​ $/bbl. excluding any gasoline octane premium.​

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Improving FCC Unit Profitability

​For many refineries meeting new, challenging ultra-low sulfur gasoline regulations 
(Tier 3) will require operating adjustments, catalyst formulation changes, and/or capital investment. Many operating strategies that reduce sulfur may reduce gasoline octane, which is often undesirable due to refinery octane requirements. Find out more about octane fundamentals and the specifics of the Tier 3 regulations through several case studies from Grace that illustrate strategies for preserving octane, maximizing alkylation rates, and reducing sulfur to maintain regulatory compliance. ​

download icon2.pngDriving Octane in an Ultra-Low Sulfur Gasoline ​Market

​​​​​Maximizing diffusion of feed into and products out of an FCC catalyst is critical to unlocking the full value potential of an FCC unit in which the riser residence time is only a few seconds.  Through a collaborative effort between Motiva, Grace, and Rive, an innovative catalyst solution incorporating Rive’s mesoporous zeolite was designed and trialed at a Motiva USGC refinery.  The trial results demonstrated the​​ significant value that this technology can bring to an FCC unit.  During and since the trial, Motiva has been able to realize uplift in the range of $0.40 to $1.20 /BBL (within the boundary of the FCC unit) depending on the market economics. 

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​Maximising Propylene in the FCC Unit​

​Collaborating to Combat 
Iron Poisoning​​​​

Comparative trials with FCC catalyst formulations identified a winner on olefins selectivity and other factors. In this case study, Grace shows the comparative advantage of our catalyst system of ProtAgon 4G/Olefins Ultra MZ. At this integrated international oil and gas company headquarterd in Vienna, the FCCU’s profitability improved due to higher propylene and isobutylene selectivity, improved dry gas selectivity, better bottoms-to-coke yield, improved bottoms upgrading, excellent attrition resistance, and somewhat lower catalyst usage. Moreover, the catalyst change did not affect CO promotion and helped maintain unit particulate and NOx emissions. Read more about the factors that went into the development of this profitable change for the refiner. 

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The growth in domestic crude production has resulted in new challenges for refiners. Elevated levels of contaminant iron in crude are becoming the norm. Downstream, iron poisonin​​g in the FCCU was once an isolated phenomena, limited to a handful of refiners processing opportunity crudes. Today, more refiners are experiencing the effects of elevated iron in the FCCU. To maintain operating flexibility and profitability, refiners need effective strategies to manage unconventional contaminant metals.

Find out more about how Philadelphia Energy Solutions collaborated​ with Grace to maintain profitable operations in a dynamic and challenging refining environment.