Grace, Catalyst Best Practices

Catalyst Best Practices

Abu Dhabi International Downstream, 10-12 May 2015

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Agenda

Takreer are about to commission the EPC FEED of their Atmospheric

Residue Desulphurization Unit (ARDS) which will utilize 3000mt of

catalysts in addition to their RFCC unit. There are three main questions

surrounding the catalyst utilized in the ARDS unit as well as the RFCC

unit:

1. What is the best way to handle and manage the vast

amounts of catalysts in these units?

2. How to optimise the use of these catalysts?

3. How to dispose of vast amounts of catalysts in an

environmentally friendly way?

4. What is the best selection method for optimum catalyst

technology?


Agenda





unit:

1. What is the best way to handle and manage the

vast amounts of catalysts in these units?





technology?


Catalyst Handling

One issue for Takreer will be to handle and manage a large

amount of FCC catalyst

Investing in Infrastructure

A local production plant in the Middle East enables catalyst reformulation time to be reduced from approximately 2 months to 1 week.

This will allow Middle East refineries to quickly optimise their FCC operation.

Phase I of the FCC Catalyst Manufacturing plant was completed recently with the capability to receive and store Fresh Catalyst, ZSM-5 additive and Spent

Catalyst

Local Production


Catalyst Handling

One issue for Takreer will be to handle and manage a large

amount of FCC catalyst

Silo facilities allows fresh catalyst to be delivered by silo truck.

This improves the working environment by eliminating problems of dust emissions associated with the use of super sacks.

Delivery: safe, fast, dust-free


Hydroprocessing Catalyst Handling

Partner with a catalyst supplier that has

loading units that are both (a) very large and (b) have a modular configuration

local supplying and storage facilities to offer flexibility in loading and schedule.

Work with an experienced catalyst handling contractor who has

loaded and unloaded units of this size previously using proven and reliable methods for dense loading, and

worked safely in live plant (ie. when the other modules are still in operation).

Partner with a catalyst supplier on a long term basis.


Agenda





unit:




3. How to dispose of vast amounts of catalysts in in an



technology?


Optimising Catalyst Usage

A key objective for Takreer is to process resid feedstock in the

FCCU while achieving the highest propylene yield, which

requires the use of different catalyst functionalities

Metals Tolerance

Grace has proposed a finely tuned resid FCC catalyst containing high zeolitestability and metals tolerance to meet Takreers resid feedstock requirements.

Grace Catalysts incorporates state of the art Vanadium trapping functionality

The catalyst also contains a balanced mesoporosity to achieve the optimumlevel of coke-selective bottoms cracking

Bottoms Upgrading


Optimising Catalyst Usage

A key objective for Takreer is to process resid feedstock in the FCCU

while achieving the highest propylene yield, which requires the use of

different catalyst functionalities

The Grace catalyst is formulated to provide the appropriate level of H-transferactivity to increase LPG olefins.

Grace proposes the additional use of the OlefinsUltra HZ additive, which is a patented technology that provides the highest propylene activity in the market

Catalyst physical properties are also important, for example, Grace catalystshave industry leading attrition resistance for minimum losses.

Propylene Selectivity Physical Properties

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Technical Service

Grace will supply industry-leading technical service and support

Optimizing unit operation

Grace provides expert advice on operational problems concerned with the mechanical integrity of the FCCU.

For example, issues such as cyclone performance, stripper efficiencies, circulation problems, transfer line problems, slurry circuit fouling, or high unit

erosion can be analysed by our technical service experts.

Grace has introduced an independent critical review service to provide a health check on FCC operations. This feature has been widely appreciated and has

assisted with shutdown planning and capital expenditure.

Troubleshooting

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Technical Service

Grace will supply industry-leading technical service and support

Grace provides regular on-site and off-site workshops specifically created for FCC process engineers covering such topics as:

feedstock properties

heat balance, mass balance

unit optimisation and troubleshooting strategies

Knowledge Sharing

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MIDAS Gold

Highest

activity, deep

conversion

resid catalyst

Used in 7

FCCs globally

2014

pre

2003

2003 2005

- 2006

2003 2009

Continuous Innovation in FCC Catalyst Technology

2003-

2009

2011

REsolution

REactoR

REduceR

ProgREss MIDAS Gold

EnhanceR

Platform

New holistic

approach to

catalyst design

Used in over 100

FCCs in EMEA

2013

ACHIEVE 400

1G 2G 3G

NEKTOR NEKTOR-ULCC NaceR

NOMUS NOMUS-DMAX DieseliseR

NADIUS ProtAgon ResidCrackeR

2015

EnhanceR 4G

ACHIEVE Series

NEKTOR-4G

ResidCrackeR-4G

NADIUS-4G

ProtAgon-4G

2013

MIDAS in EMEA

High matrix

bottoms cracking

catalyst

Used in over 120

FCCs globally

ACHIEVE 400

Maximum octane

and butylene

selectivity

Used in 3 FCCs in N. America

MIDAS

REpLaCeR

Rare-earth free

FCC catalysts

Used in over

170 FCCs

2011

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Next Generation of EnhanceR Catalysts

Grace has developed 4th generation EnhanceR catalyst families,

including:

Over 70% of all residue FCCUs in EMEA use Graces EnhanceR technology

NEKTOR-4G

Coke selecvityfor resid feeds

ResidCrackeR-4G

Bottoms upgrading for resid feeds

Nadius-4G

High activity for low metals

feeds

ProtAgon-4G

Propylene Maximisation

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How to optimize hydroprocessing catalyst use?

Partner with an leading catalyst supplier that has strong technical

service to help manage the run and optimize catalyst life.

This is important for modular operation where the catalyst life of

each module is monitored and optimized separately in order to

achieve constant product properties between the RFCC

turnarounds.

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Agenda





unit:







technology?

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Sustainable Solutions

Grace recognises the importance of providing sustainable

solutions

Catalyst Life Cycle Management

Grace has a permit to collect, store, handle, reprocess and re-sell Ecat and

fines generated from Grace manufactured

FCC catalysts.

For Ecat high in contaminant metals, Grace has an agreement to rework such

materials through

various outlets, which is fully in compliance

with REACH regulations.

To date Grace has safely exported and reworked over 30,000 MT of spent catalyst

from Orpic.

This has been achieved in an environmentally-friendly manner under

Graces REACH registration umbrella.

Work with an experienced metals reclaimerwho has a track record of safely handling

hazardous waste.

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Agenda





unit:






4. What is the best selection method for optimum

catalyst technology?

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Catalyst Selection

To prepare a proper catalyst selection andminimize risk following procedure ishighly recommended:

Physical Testing To prevent severe issues in the commercial unit from

problematic attrition resistance as well as fluidisationproperties.

Catalytic benchscale or riser pilot plant testing Deactivation in a robust protocol like CPS-3 after

metals impregnation to e-cat metals level.

Yield prediction based on constant coke yieldresults using state of the art FCC model

Enables comparison at constant feed rate and heatbalance

Activity retention is considered at constant CAR

Provides the accuracy required for unit operating andperformance changes

Model optimisation of the operation To select the most economic catalyst technology

A catalyst selection study is the only way to compare different

catalyst technologies on a comparable basis!

For additional information, please visit www.grace.com

Grace, Catalyst Best Practices

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