|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.|
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.
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.