ResidCrackeR™ 4G - W. R. Grace and Company · ResidCrackeR™ 4G is the latest in a long line of...
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ResidCrackeR™ 4G is the latest generation of Grace’s coke- selective bottoms cracking ResidCrackeR™ catalyst family for residue FCC feed applications. ResidCrackeR™ 4G is an extension of the ResidCrackeR™ catalyst family, a component of the EnhanceR™ technology platform, which is the market leader in the EMEA region (Fig. 1). ResidCrackeR™ 4G incorporates new technologies that were developed during the extensive Grace R&D program that was initiated as a result of the tight oil boom in North America and the new challenges faced by European refineries. This R&D program resulted in advances to the following five functionalities: • Higher Diffusivity Matrices • Flexible Hydrogen Transfer • Higher Activity • Advanced Metals Tolerance • Dual Zeolite Functionality. As shown in Fig. 2, ResidCrackeR™ 4G features higher diffusivity matrix, advanced metals tolerance and flexible hydrogen transfer. 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 Fig. 3. ResidCrackeR™ 4G technology improved bottoms upgrading into LCO while maintaining coke selectivity in Refinery B. ResidCrackeR™ 4G Case Study ResidCrackeR™ 4G was successfully used in Refinery B. Refinery B operates a 30,000-barrel-per-day FCCU and was seeking to improve bottoms upgrading into max LCO, within the regenerator temperatures and air blower limitations. ResidCrackeR™ 4G provided a 1-2wt% boost in LCO yield through enhanced bottoms upgrading, as illustrated in Fig. 3, without compromising the excellent coke selectivity of the base catalyst. ResidCrackeR™ 4G Fig. 1. ResidCrackeR™ 4G belongs to Grace’s EnhanceR™ technology platform, EMEA market leader for residue applications. Higher Diffusivity Matrices Dual Zeolite Technology Flexible Hydrogen Transfer Higher Activity Advanced Metals Tolerance Fig. 2. New functionalities utilized in ResidCrackeR™ 4G. ResidCrackeR™ 4G Reference catalyst Coke yield (%) 3.2 18 19 20 21 22 23 3.6 4.0 4.4 4.8 LCO (wt%) The use of ResidCrackeR™ 4G resulted in better bottoms upgrad- ing into LCO while maintaining excellent coke selectivity. The FCC unit at Refinery B was able to increase its operating window and process more residue. ResidCrackeR™ 4G catalysts bring the following performance benefits to unit operations: • premium bottoms upgrading • selective cracking towards LCO • excellent coke selectivity • excellent attrition resistance ResidCrackeR™ 4G catalysts are fully compatible with all Grace additives. # of EnhanceR™ applications
Transcript of ResidCrackeR™ 4G - W. R. Grace and Company · ResidCrackeR™ 4G is the latest in a long line of...
ResidCrackeR™ 4G is the latest generation of Grace’s coke-selective bottoms cracking ResidCrackeR™ catalyst family for residue FCC feed applications.
ResidCrackeR™ 4G is an extension of the ResidCrackeR™ catalyst family, a component of the EnhanceR™ technology platform, which is the market leader in the EMEA region (Fig. 1).
ResidCrackeR™ 4G incorporates new technologies that were developed during the extensive Grace R&D program that was initiated as a result of the tight oil boom in North America and the new challenges faced by European refineries.
This R&D program resulted in advances to the following five functionalities:• Higher Diffusivity Matrices• Flexible Hydrogen Transfer• Higher Activity• Advanced Metals Tolerance• Dual Zeolite Functionality.
As shown in Fig. 2, ResidCrackeR™ 4G features higher diffusivity matrix, advanced metals tolerance and flexible hydrogen transfer.
2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014
# of EnhanceR applications
Fig. 3. ResidCrackeR™ 4G technology improved bottoms upgrading into LCO while maintaining coke selectivity in Refinery B.
ResidCrackeR™ 4G Case Study
ResidCrackeR™ 4G was successfully used in Refinery B. Refinery B operates a 30,000-barrel-per-day FCCU and was seeking to improve bottoms upgrading into max LCO, within the regenerator temperatures and air blower limitations.
ResidCrackeR™ 4G provided a 1-2wt% boost in LCO yield through enhanced bottoms upgrading, as illustrated in Fig. 3, without compromising the excellent coke selectivity of the base catalyst.
ResidCrackeR™ 4G
Fig. 1. ResidCrackeR™ 4G belongs to Grace’s EnhanceR™ technology platform, EMEA market leader for residue applications.
Higher Diffusivity Matrices
Dual Zeolite Technology
Flexible Hydrogen Transfer
Higher Activity
Advanced Metals Tolerance
Fig. 2. New functionalities utilized in ResidCrackeR™ 4G.
ResidCrackeR™ 4G
Reference catalyst
Coke yield (%)
3.218
19
20
21
22
23
3.6 4.0 4.4 4.8
LCO
(wt%
)
The use of ResidCrackeR™ 4G resulted in better bottoms upgrad-ing into LCO while maintaining excellent coke selectivity. The FCC unit at Refinery B was able to increase its operating window and process more residue.
ResidCrackeR™ 4G catalysts bring the following performance benefits to unit operations:
• premium bottoms upgrading• selective cracking towards LCO• excellent coke selectivity• excellent attrition resistance
ResidCrackeR™ 4G catalysts are fully compatible with all Grace additives.
# of EnhanceR™ applications
The information contained herein is based upon our testing and experience and is believed to be accurate. Since operating conditions may vary and since we do not control such conditions, we must disclaim any warranty, express or implied, with regard to results to be obtained from the use of our products or with regard to application of GRACE techniques. January 2015
W. R. Grace & Co.-Conn. | 7500 Grace Drive | Columbia, MD 21044 | USA | +1.410.531.4000 | www.grace.com
Grace Refining Technologies
Our sales representatives in your region
W.R. Grace & Co. Refining Technologies7500 Grace Drive Columbia, MD 21044 USA Phone: +1 (410) 531-4000
Grace GmbH & Co. KGIn der Hollerhecke 1, 67547 Worms, GermanyPhone: +49 (6241) 403-00
W.R. Grace Singapore PTE Ltd.230 Orchard RoadFaber House#09-232Singapore 238854Phone: (65) 6265 3033
Technical ServiceAn equally critical component associated with processing challenging feeds is solid technical service support. Grace has been providing industry-leading technical service to the refining industry since 1947.Grace’s experienced engineers support FCC customers with:• Application and operations expertise • Start-up and optimization assistance • Industry benchmarking • Feed characterization and pilot plant studies
Understanding feed impacts earlier allows opportunity to optimize the operating parameters and catalyst management strategies, enabling a more stable and profitable operation.
InnovationResidCrackeR™ 4G is the latest in a long line of Grace’s innovation in catalyst technology, and is the product of Grace’s global team of research scientists.
MIDAS® Gold
Highest activity, deep conversion resid catalyst
Used in 7 FCC’s globally
2014
pre
20032003 2003
2003-2009
REsolution™REactoR™REduceR™ProgREss™
MIDAS®
Gold
EnhanceR™
New holistic approach to catalyst design
Used in over 100 FCC’s in EMEA
2013
ACHIEVE ® 400
1G 2G 3G
NEKTOR™ NEKTOR-ULCC NaceR
NOMUS™ NOMUS-DMAX DieseliseR
NADIUS™ ProtAgon™ ResidCrackeR
2015
EnhanceR 4G
ACHIEVE® Series
2013
MIDAS® in EMEA
High matrix bottoms cracking catalyst
Used in over 120 FCC’s globally
ACHIEVE® 400
Maximum octane and butylene selectivity
Used in 3 FCC’s in N. America
MIDAS®
REpLaCeR® Rare-earth free FCC catalysts
Used in over 170 FCC’s
2011
NEKTOR™ 4GResidCrackeR™ 4GNADIUS™ 4G ProtAgon™ 4G
™ 4G
™
Platform
Fig. 4. ResidCrackeR™ 4G catalysts result from Grace’s innovation in FCC catalyst technology.
