Focused. TAKREER Research Centre & Grace · TAKREER Research Centre & Grace: ... Davison Chemicals,...
Transcript of Focused. TAKREER Research Centre & Grace · TAKREER Research Centre & Grace: ... Davison Chemicals,...
1 W. R. Grace & Co.TRC & Grace: Providing value through a successful cooperation
Focused.
Innovative.
Performance
Driven.
Dr. Gnana Pragasam | TRC
Mr. Silviu Serban | Grace
Dr. Christoph Fougret | Grace
Abu Dhabi International Downstream
September 18th -19th 2017
TAKREER Research
Centre & Grace:Providing value through a
successful cooperation
2 W. R. Grace & Co.TRC & Grace: Providing value through a successful cooperation
The Only Constant in Refining Is Change
▪ Shift in demand and production
from mature markets to rapidly
growing markets
▪ New crudes and alternative
feedstocks
▪ Changing product demands and
what refiners can manufacture
▪ Complex regulatory environments
▪ Margin pressures
3 W. R. Grace & Co.TRC & Grace: Providing value through a successful cooperation
Modern Refiner Challenges
The most profitable refiners are the ones that leverage their
flexibility to capture market opportunities
CrudePrice, quality and
availability
ProductsCrack spreads and supply-
demand balance
LegislationEnvironmental emissions
and product properties
Operating ConstraintsUnit and downstream
Challenges
▪ Shifting crude slates
▪ Unconventional or
opportunistic crudes
▪ New trade flows
▪ Shifting economics
▪ Fuels vs. petrochemical
feedstocks
▪ Environmental compliance
▪ Fuels quality/specifications
▪ Emissions
4 W. R. Grace & Co.TRC & Grace: Providing value through a successful cooperation
Collaboration Helps Overcome Challenges Quickly
Access to Resources
Market Intelligence
Risk Minimization
Value
of
Partnerships
New
Markets
New
Processes
New
Products
Speed
5 W. R. Grace & Co.TRC & Grace: Providing value through a successful cooperation5
Six Core Strengths of a Great Catalyst Partner
Materials Science Leadership
1. History of innovation and industry leading technology, matched with
corporate commitment to invest for the future
2. Extensive and knowledgeable R&D teams with strong analytical
capabilities
Global Manufacturing Capabilities
3. Manufacturing expertise and flexible production
4. Global presence with broad product portfolio
Customer Focus
5. Long-term relationships built on trust
6. Deep industry knowledge, application and problem-solving expertise
6 W. R. Grace & Co.TRC & Grace: Providing value through a successful cooperation
In The Beginning
The Development of Fluid Catalytic Cracking
▪ The FCC process was developed to meet the need
for high octane aviation fuel
▪ Catalytic Research Associates (CRA) formed to
develop a powdered catalytic cracking process
▪ World’s first FCC unit (PCLA #1)
▪ Started operation May 1942 in Baton Rouge, Louisiana
▪ Built by M.W. Kellogg
▪ Owned and operated by Standard Oil of New Jersey
▪ Catalyst (synthetic silica-alumina) supplied from
Davison Chemicals, now W. R. Grace & Co.
Collaboration between refiners, engineering companies and
catalyst companies lead up to new technologies
7 W. R. Grace & Co.TRC & Grace: Providing value through a successful cooperation
FCC Technology Development
Outstanding Discoveries
▪ The discovery of Y-zeolite in 1962 revolutionized FCC
catalysts. The zeolite, developed by Mobil, was
commercialized by Grace
▪ Grace working in conjunction with Mobil developed the
first ZSM-5 additive for use in fluid cat crackers in
1986
New catalysts and collaborations contributed
to FCC’s success
Environmental Challenges
▪ Particulate emissions under scrutiny with success of FCC
process in the 1940’s
▪ Solution = hardware + catalyst (Two Stage Cyclones and Trickle Valves,
Microspheroidal (MS) Catalyst)
▪ Environmental awareness of the 1960’s and 1970’s
▪ CO & SOx reduction
8 W. R. Grace & Co.TRC & Grace: Providing value through a successful cooperation
Low Sulfur Fuels
Ultralow Sulfur Diesel
▪ Grace and ExxonMobil initiated a joint development program in 1998, which resulted
in the GSR® 5 and SuRCA® technologies for FCC gasoline sulfur reduction.
▪ 7 patent families, jointly owned.
▪ GSR® 5 and SuRCA® used by more than 35 refineries worldwide.
Innovation through collaboration to satisfy regulations and
meet demand
Low Sulfur Gasoline
▪ Chevron and Grace joined together in 2001 to form Advanced Refining
Technologies (ART).
▪ Technology expertise, world-class research and development, global
manufacturing and technical support footprint, and a complete portfolio
of hydroprocessing catalysts designed to meet the challenges of today's
refiners.
9 W. R. Grace & Co.TRC & Grace: Providing value through a successful cooperation
Middle Distillates Maximization
DieseliseR™
In 2006 Grace and Repsol started a joint collaboration project to develop
a new generation of catalysts for middle distillates maximization
in hydrotreated feedstock scenarios.
▪ A total of 19 catalysts were evaluated in the first round to select the best zeolite, matrix
and post-treatments.
▪ The catalyst that showed the best performance in both a high and low metals scenario,
the DieseliseR-Sol 16 catalyst, was manufactured by Grace on an industrial scale and
successfully used in Puertollano’s refinery
▪ More applications have benefit from DieseliseR catalyst performance since then.
„Catalysts for maximising middle distillates“ - PTQ Q1 2012
Collaboration in catalyst development and application, from
laboratory scale to commercial operation, enabled refineries
to achieve production objectives
10 W. R. Grace & Co.TRC & Grace: Providing value through a successful cooperation
Grace Provides Partnership, Not Just Products
Working Closely with Customers to Improve Their
Products and Processes
TRC & Grace: a profitable synergy for TAKREER
▪ Our customers inspire our innovation. We
tailor our products to meet unique customer
performance needs.
▪ We gain deep understanding of our
customers’ manufacturing processes and
formulations.
▪ Close collaboration with our customers
enables quick adjustments to changing
market demands.
▪ We are constantly researching and
developing new products in anticipation of
future market needs.
▪ We invest in R&D and regional support teams
to address local customer requirements.
11 W. R. Grace & Co.TRC & Grace: Providing value through a successful cooperation
Sharing Best Practices
TRC and Grace Cooperation
Advances in fluid cracking catalyst technology are dependent upon the
ability to accurately determine catalyst performance in the laboratory and to
relate it to commercial performance.
FCC Catalyst Characterization Methods:
▪ Calcination
▪ Deactivation of FCC catalyst and of FCC additives
▪ Impregnation Methodologies & Steaming procedures
▪ Evaluation
▪ Fixed bed / fixed fluidized bed / pilot riser
▪ Analyses of the testing products
12 W. R. Grace & Co.TRC & Grace: Providing value through a successful cooperation
Sharing Best Practices
Comparison of Methods
▪ Round robin measurements
▪ Deactivation comparison
▪ ACE methods comparison
▪ Attrition methods comparison
▪ Ecat analysisIncl. physical & chemical analyses plus catalytic testing
Support on Method Development
• XRF Collaboration / Calibration assistance
13 W. R. Grace & Co.TRC & Grace: Providing value through a successful cooperation
Committed to Success
14 W. R. Grace & Co.TRC & Grace: Providing value through a successful cooperation
TRC
History timeline
2004
Takreer and IKC start TRC study
2010
First Pilot plant commissioned
2013
8 new pilot plant including FCC Ace unit commissioned
2012
TRC officially inaugurated
2015+TRC entered full operation mode2006
MOA signed between Takreer and JCCP
2008
ADNOC CPD awarded TRC building project
2005
TRC project approved by Takreer
ST
AR
TS
TA
RT
15 W. R. Grace & Co.TRC & Grace: Providing value through a successful cooperation
TRC
TRC vision and mission
THE MISSION
THE VISION
16 W. R. Grace & Co.TRC & Grace: Providing value through a successful cooperation
TRC R & D goal and objectives
Deliver high level, reliable and
repeatable results allowing direct
positive impacts on everyday
Takreer’s operations .
Develop pilot-ready technologies (TRL
4-6) and evaluate new technologies
within ADNOC’s Group R&D
Manage efficiently R&D Portfolio,
geared towards technology transfer
and deployment
O B J E C T I V E S
DEVELOP AND DEPLOY NEW TECHNOLOGIES
through a balanced portfolio of R&D projects
enabling highest recovery from oil and gas fields,
and efficient exploration
BUILD AN EMIRATI-STRONG WORKFORCE
Post-graduates engineers and researchers to
carry forward the development and deployment
of innovative technologies
To be a Technology Advisor for Takreer
refineries by supporting Takreer core refining
activities
CORE REFINING TECHNOLOGY SUPPORT
G O A L S
1. Catalyst Management support
2. Process Optimization support
3. Integrity & Reliability improvement
support
CORE REFINING TECHNOLOGY
SUPPORTDEVELOP AND DEPLOY NEW TECHNOLOGIES
1. Supporting Takreer’s sustainable oil refining
ambitions
2. Focusing on nurturing the right mix of local
talents
3. Allow for a balanced IP portfolio showcasing
Takreer’s ability to develop and deploy new
technologies
BUILD AN EMIRATI-STRONG
WORKFORCE
1. Scholarship program
2. Dedicated work related training
3. International scientific Promotion
17 W. R. Grace & Co.TRC & Grace: Providing value through a successful cooperation
TRC
TRC-Grace
▪ TRC-Grace partnership for the RFCC catalyst development
The long term partnership involves close collaboration between TRC and Grace, to provide
successful outcomes in areas of joint interest
▪ Joint collaboration work for new product development
Grace, the FCC catalyst supplier of TAKREER FCC unit, continually make innovations in catalyst
technology, to allow FCC units to better adapt to the changing production scenarios.
▪ Ecat lab alignment
Regular cross evaluation of samples between TRC and Grace as continual check on accuracy and
precisions for critical analysis
▪ Process optimisation
Quick feedback increases the usefulness of the data to refinery, providing valuable support in
monitoring the condition of the circulating catalyst inventory, and the status of FCC unit operations.
18 W. R. Grace & Co.TRC & Grace: Providing value through a successful cooperation
Poll Question
What is for you the most important element to
establish a collaboration project between
Refinery R&D and FCC Catalyst supplier?>
a. Catalysts are a key part of the solution
b. Collaboration is needed to develop synergies
c. Catalyst partners are solution providers
d. There is a high Value in collaboration
19 W. R. Grace & Co.TRC & Grace: Providing value through a successful cooperation
Conclusions
Speed to market and
Rapid development
Manufacturing
expertise and capacity
Technical support,
experience and tools
Collaboration and
partnership
Catalyst
Optimization
and Innovation
▪ Zeolite Stability &
Modifications
▪ Matrix Technology
Advances
▪ Improved Metals
Tolerance
▪ Gasoline Sulfur
Reduction
THE VALUE WE BRING:
TRC
20 W. R. Grace & Co.TRC & Grace: Providing value through a successful cooperation