Optimizing FCC Operations in a High Rare-Earth Cost World: Commercial Update on Grace Davison's Low and Zero Rare-Earth FCC Catalysts
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Optimizing FCC Operations in a High
Rare-Earth Cost World: Commercial
Update on Grace Davison’s Low and
Zero Rare-Earth FCC Catalysts
Olivia Topete In 1992 Chinese leader Deng Xiaoping declared, “The Middle East has its oil, China has rare earth; China's
Technical Sales rare earth deposits account for 80 percent of identified global reserves, you can compare the status of these
Representative reserves to that of oil in the Middle East: it is of extremely important strategic significance; we must be sure
to handle the rare earth issue properly and make the fullest use of our country's advantage in rare earth re-
Grace Davison sources.”1
Houston, TX, USA
In actuality, rare earth controversies between China and the West are not new. In the second half of 2010,
however, the gravity of China’s market dominance over rare earth resources peaked. The price of lan-
Colin Baillie
thanum began a zealous climb to levels never before seen. Catalysts are generally a refinery's second-
Marketing Manager
highest raw material cost after crude oil. It is therefore not surprising that refiners are increasingly asking
Grace Davison catalyst suppliers to relieve their cost pressures while maintaining or even improving product performance.
Worms, Germany A year later, the escalation has abated, but lanthanum prices remain 12x's higher than the base level in
early 2010.
Rosann Schiller Grace has been diligently working to achieve solutions that would either lower or fully eliminate rare earth
Senior Marketing content of FCC catalyst without sacrificing performance. In 2011, Grace Davison Refining Technologies
Manager launched the REpLaCeRTM family of zero- and low-rare-earth FCC catalysts.2 This new series includes five
new catalysts for both hydrotreated and resid feed processing with zero and low rare earth content, and
Grace Davison their successful commercialization will be discussed.
Columbia, MD, USA
The Role of Rare Earth in FCC Catalysts
Lanthanum and cerium are the two main rare earths (RE) used in FCC catalysts. These metals limit the ex-
tent to which zeolite dealumination occurs (thus stabilizing the structure) under the conditions of the FCC
unit. The aluminium atoms within the zeolite structure are the primary catalytic sites in FCC catalysts and
therefore play an important role in providing activity and selectivity. For example, a higher amount of alu-
minium atoms will increase the amount of hydrogen-transfer reactions that occur. Such reactions compete
2 ISSUE No. 110 / 2011
with cracking reactions and
are important for preserving 20%
Percent Reduction in RE, wt.%
molecules in the gasoline 18%
range. Therefore, by restrict- 16%
ing the loss of aluminium 14%
12%
atoms in the zeolite, rare
10%
earth increases the activity
8%
and gasoline yield of FCC 6%
catalysts. Rare earth also 4%
plays an important role to 2%
prevent metals deactivation, 0%
Time
as it is a very effective vana-
Percent Reduction in RE, wt.%
dium trap. Therefore, for
resid processing in particular,
RE metals play an important FIGURE 1: RE 2 O 3 , wt.% Versus Date
role in maintaining stability
and activity.
Grace Davison has a long
history of providing innova-
tion in the development of
FCC catalysts, including the
addition of rare earth metals
to stabilize the zeolite Y
component of the FCC cata-
lyst. Grace also introduced
RE free zeolites, that were
extremely popular in the 80-
90’s, which delivered high
gasoline octane as well as
stable activity. Grace Davi-
son has now developed the
REpLaCeRTM family of zero-
and low-rare-earth FCC cat-
alysts, which are based on
two rare-earth free Z-21 and many refiners have pursued The GENESIS® catalyst sys- ance in a broad range of
Z-22 zeolites, utilizing propri- more traditional avenues of tem provides the ultimate feeds, IMPACT® also gained
etary stabilizing compounds reformulation to achieve a flexibility to optimize Z/M in recent recognition for an-
and unique manufacturing lower rare-earth solution each unique application.3 other characteristic – high
processes to deliver similar without sacrificing unit per- The fundamental component rare earth content.
or even improved perform- formance. One such cus- is MIDAS® which maximizes
ance compared to rare-earth tomer, Refiner A, worked conversion of bottoms with In the new GENESIS® LX
containing catalysts. with Grace Technical Serv- excellent coke selectivity by catalyst formulation, a lower
ices to reduce the RE level converting coke precursors RE high zeolite Aurora® alu-
by nearly 20% via a reformu- into liquid products. The mina sol catalyst replaced
lation of GENESIS® to GEN- other component, as was the
Reducing Rare IMPACT®. The Ecat Re2O3
ESIS® LX. This was case here, is often IMPACT®.
Earth via trend is shown in Figure 1.
accomplished without detri- The inclusion of IMPACT®
Traditional Although the reduction in
ment to unit operating objec- provides critical zeolite sur-
Means rare-earth content seems
tives of maintaining face area and activity. Most modest, this did in fact,
While the Grace Davison’s conversion and bottoms up- prominently known for its su- equate to substantial sav-
zero rare-earth RepLaCer™ grading. perior coke selectivity, gas ings. Using third quarter
catalyst family is gaining selectivity, and metals toler- 2011 AMI averages, the re-
commercial momentum,
GRACE DAVISON CATALAGRAM® 3
finery recognized a savings
of over $1,000 per ton.
10
MAT Value of GENESIS®
After reformulation, Refiner A 8
Delta from the Median
not only realized some re-
6
prieve from rising rare-earth
4
costs but also benefits to unit
operation. The fresh activity 2
GENESIS LX is two numbers
®
0
higher than the previous GEN- -2
ESIS® grade. The activity
-4
boost is maintained within the Time
unit as shown in Figure 2.
GENESIS® GENESIS® LX
Some variability in the Ecat
activity data is present and
FIGURE 2: MAT Activity is Maintained at Lower Rare Earth
can be attributed to the
volatility in feed quality and
metals levels. As verified via
Figure 3, the catalyst weath-
ers the fluctuations without
difficulty and realizes a two
to three number activity in-
crease in the unit.
10
MAT Value of GENESIS®
8
Delta from the Median
The reformulation to GENE-
SIS® LX also bestowed addi- 6
tional conversion to the unit 4
as expressed in Table 1. Re- 2
finer A benefited from a small 0
decrease in catalyst addi-
-2
tions.
-4
The higher Ecat pore volume V + Na, wppm
inherent to the new reformu-
GENESIS® GENESIS®LX
lation in tandem with the in-
creased activity yielded
improved bottoms conver- FIGURE 3: Activity is Higher with Lower Rare Earth at Equivalent Metals
sion, as well.
Reducing Rare
Earth with
ALCYONTM
GENESIS® GENESIS® LX
Corrected Conversion, ∆ from Base
and ENCORETM
BASE 1 lv.%
Akin to Refiner A, Refiner B
Conversion / Feed API, ∆ from Base
Catalyst Additions, % Reduction BASE 15%
employed a catalyst that also
contained the innovative BASE 0.02
resid catalyst, IMPACT®. As Slurry / Slurry API, ∆ from Base
Slurry / Pore Volume, ∆ from Base
BASE -1.0
a unit that operates on the BASE -3.2
higher end of the Ecat met-
als spectrum, Refiner B TABLE 1: Refiner A FCC Unit Data
needs to maintain activity
4 ISSUE No. 110 / 2011and bottoms upgrading with-
out an increase in dry gas
RE2O3, wt.% on Ecat
production. Until mid 2010,
100% IMPACT® easily and
economically achieved these
objectives. The exacerbat-
ing predicament, of course,
was the increasing cost as-
sociated with rare earth cata- Time
lyst content.
ALCYONTM/ENCORETM IMPACT®
Utilizing ENCORETM, a high
quality spent catalyst, Grace FIGURE 4: RE 2 O 3 , wt.% Versus Time
formulated a solution with
the ultra-active ALCYONTM
catalyst.4 With ENCORE™
in the mix, Refiner B was IMPACT® ALCYONTM/ENCORETM
subject only to the sur- 40% Turnover
charges associated with the Conversion 63 63
ALCYON TM catalyst. This re- Catalyst to Oil Ratio 7.7 6.6
lieved them of a significant Dry Gas, wt.% 2.0 1.9
portion of the cost imposed
by rare-earth hyperinflation.
Propylene, wt.% 3.9 3.9
Propane, wt.% 0.8 0.8
The eventual result will be a
Total C4=s, wt.% 4.8 4.9
significant reduction in overall
IsoButane, wt.% 2.0 2.8
rare-earth catalyst content.
n-C4, wt.% 0.7 0.6
ENCORE™ contributes
roughly half of the rare earth LPG, wt.% 13.3 13.1
added to the unit. Note that
Refiner B uses a SOx reduc- Gasoline, wt.% 42.9 43.6
tion additive that also contains LCO, wt.% 25.5 25.8
rare earth. Accordingly, the Bottoms, wt.% 11.5 11.1
rare earth observed on Ecat is
a shared contribution from Coke, wt.% 4.7 4.6
both the catalyst and the addi-
tive and the downward trend
RON 92.7 92.7
is variable. The slight upward
MON 80.9 80.7
trend illustrated in Figure 4 is
a result of increased SOx ad- TABLE 2: Refiner B ACE Test Constant Conversion Yields
ditive injection.
Inherent to the testing proto-
col, feed type and reactor
temperature were held to
produce the constant conver-
sion yields shown in Table 2.
Results establish that the re-
formulation successfully pro-
vides Refiner B with
GRACE DAVISON CATALAGRAM® 5considerably more activity. In fact, the catalyst is approximately 4.5
wt.% more active as shown in Figure 5. Figures 6 and 7 illustrate in-
8.5
creases in gasoline and 1 wt.% lower bottoms per unit of coke. AL-
8.0
CYONTM/ENCORETM catalyst was able to achieve these improved
7.5
yields without an increase in dry gas. Nearing 50% turnover, the unit
7.0
C/O Ratio
continues to show the responses exhibited in the ACE study.
6.5
6.0
5.5
5.0
Reducing Rare Earth with
4.5
50 55 60 65 70 ResidUltra™
Conversion, wt.%
Debuting in the first quarter of 2011, ResidUltraTM catalyst technol-
ALCYONTM/ENCORETM IMPACT®
ogy utilizes a re-optimized version of the ground-breaking IMPACT®
matrix functionality for metals trapping and bottoms cracking tech-
FIGURE 5: ALCYON T M /ENCORE T M Delivers Higher nology.
Activity
Relative to IMPACT®, the ResidUltraTM catalyst reduces rare earth
content by 40% without sacrificing activity or selectivity. Commercial
experience proves that unit performance between IMPACT® and
ResidUltraTM is nearly interchangeable (see article on page 13).
Refiner C employed a GENESIS® catalyst system made up primarily
45
of IMPACT®. Refiner C replaced the IMPACT® component with
44
ResidUltraTM and similar to the prior examples, desired equivalent
C5+ Gasoline, wt.%
43
performance at lower rare earth. Although still in the midst of
42
turnover, the goal is an eventual reduction in overall fresh rare earth
41 requirement of 35%.
40
39 Thus far, the unit is nearing a turnover of 85% from GENESIS® to
GENESIS® LX as illustrated in Figure 8.
38
50 55 60 65 70
Conversion, wt.%
Despite the reduction in rare earth content, the Ecat unit cell size has
ALCYONTM/ENCORETM IMPACT®
remained constant. This is vital to maintaining catalyst activity in the
unit.
FIGURE 6: ALCYON T M /ENCORE T M Improves Gasoline
Selectivity An ACE study was performed against the original GENESIS® grade
at 50% turnover to the GENESIS® LX containing ResidUltraTM . The
difference in rare earth between the base case and the reformulation
was 15%. Other key catalyst properties were essentially constant.
Specifically, both samples had similar Ni, V and Na levels, and Ecat
surface area. This unit does add ZSM-5, and the GENESIS® LX
18
17 sample, did contain a higher amount of additive (approximately 2%).
16
15
As is the standard, feed type and reactor temperature were held un-
Bottoms, wt.%
14
changed to produce the constant conversion yields shown in Table
13
12 3. ACE results indicate that relative to the base catalyst, GENESIS®
11 LX delivers benefit beyond simply a reduction in rare-earth costs. At
10
just 50% turnover, GENESIS® LX is more active by over 1 wt.% and
9
contributes nearly 1.5 wt.% to 2.0 wt.% additional conversion at con-
8
3 3.5 4 4.5 5 5.5 6
stant coke. As a result of the higher activity and improved coke se-
Coke, wt.% Feed
lectivity, GENESIS® LX catalyst produces lower bottoms yield.
TM
ALCYON /ENCORETM IMPACTTM
In an effort to abate any uncertainty related to the equivalency of the
FIGURE 7: ALCYON T M /ENCORE T M Improves Bottoms two catalysts, it is worth acknowledging that there is a shift in the
Upgrading LPG and gasoline yield. Notice from Table 3 that GENESIS® LX is
6 ISSUE No. 110 / 2011offering more LPG and gaso-
line octane. Conversely,
there is a decrease in gaso-
RE2O3, wt.% on Ecat line make. These shifts are
produced by increased levels
of ZSM-5. Both grades
would demonstrate similar
wet gas and gasoline yields
at equal additive levels.
Unit Cell Size, Å
Confirming the ACE results,
the unit demonstrates that hy-
drogen make on both cata-
lysts is very similar. The gas
factor is effectively indistin-
guishable between the two
Time grades containing ZSM-5.
Commercial data showing
GENESIS®/ZSM-5 GENESIS® LX/ZSM-5 this is contained in Figure 9.
FIGURE 8: RE 2 O 3 Was Decreased Yet Unit Cell Size Remained Constant
Genesis® / Genesis® LX /
ZSM-5 ZSM-5
50% Turnover
Conversion 69 69
Catalyst to Oil Ratio 7.7 7.1
Dry Gas, wt.% FF 2.1 2.2
Hydrogen Yield, SCFB
Propylene, wt.% FF 4.5 5.7
Propane, wt.% FF 1.2 1.3
Total C4=s, wt.% FF 4.8 5.0
IsoButane, wt.% FF 4.0 4.4
n-C4, wt.% FF 0.9 0.0
LPG, wt.% FF 15.5 18.2
Gasoline, wt.% 46.9 44.4
Gas Factor
LCO, wt.% 22.3 21.0
Bottoms, wt.% 8.7 9.1
Coke, wt.% 4.5 4.0
TABLE 3: Refiner C ACE Test Constant Conversion Nickel Equivalent, ppm
Yields
GENESIS®/ZSM-5 GENESIS® LX/ZSM-5
FIGURE 9: Ecat Gas Selectivities are Maintained
GRACE DAVISON CATALAGRAM® 7Moving
Towards
Elimination of
RE2O3, wt.% on Ecat
Rare Earth
with
REMEDY™
Refiner D operated with a
grade of GENESIS® LX that
contained 1.3 wt.% rare
earth. Taking the ultimate
step in minimizing the impact Time
on catalyst cost, the AURO-
GENESIS® LX/OlefinsMax® REMEDYTM/OlefinsMax®
RATM component of the
GENESIS® LX catalyst sys-
tem was replaced with the FIGURE 10: RE 2 O 3 Versus Time
zero rare earth REACTORTM
technology. REACTORTM is
formulated with Z-22, which
uses a proprietary non-rare-
earth compound to stabilize 4
Delta from the Median MAT
the zeolite. The rare earth 3
Value of GENESIS® LX
content of the new catalyst 2
system, REMEDY , is half 1
TM
that of the previous GENE- 0
SIS® LX.
-1
-2
Figure 10 illustrates the
-3
steady reduction in rare-
-4
earth content as the unit
Time
turns over to REMEDYTM.
GENESIS® LX/OlefinsMax® REMEDYTM/OlefinsMax®
At approximately 65%
turnover to REMEDYTM, the
FIGURE 11: Ecat MAT is Maintained Despite the Reduction in Rare Earth
performance of the unit is
analogous to what was ob-
served while operating on
GENESIS® LX. Figure 11
demonstrates that Ecat MAT 4
Delta from the Median MAT
has been preserved as the
Value of GENESIS® LX
3
unit continues to increase
2
the level of REMEDYTM in
1
the circulating inventory. Ev-
0
ident from Figure 12, the re-
-1
sponse to metals is
-2
equivalent if not better when
-3
compared to the rare earth
-4
analog, GENESIS® LX. 75% 80% 85% 90% 95% 100%
Percent of Maximum V + Na, wppm Observed
GENESIS® LX/OlefinsMax® REMEDYTM/OlefinsMax®
FIGURE 12: Metals Tolerance of REMEDY T M Is Equivalent or Better than GENESIS® LX
8 ISSUE No. 110 / 2011Even with higher metals lev- Consistent with refiner feed-
els, REMEDYTM shows back, Ecat analysis, and
equivalent or lower Ecat hy- ACE testing, activity has
drogen scfb, gas factor, and been maintained and hydro-
coke factor. This is illus- gen make reduced with
Hydrogen Yield, SCFB
trated in Figure 13. REMEDYTM.
ACE testing of Ecat samples Figure 14 exhibits additional
was performed against the ACE test findings, where the
original GENESIS® LX grade coke selectivity of REME-
at 40% turnover to DYTM delivers greater gaso-
REMEDYTM. The two sam- line selectivity and superior
ples tested were equivalent bottoms upgrading over the
in Ni, V and Na levels as well base GENESIS® LX.
as Ecat surface area. ACE
Gas Factor
testing confirms the trends The breadth of the Grace
that have been observed in portfolio presents refineries
the routine Ecat analyses as with a myriad of RE reduc-
shown in Table 4. In addition tion options. As demon-
to the advantages of ZSM-5, strated, scrutinization of
further benefits from the new market driven operating
catalyst system are already
surfacing.
Coke Factor
GENESIS® LX REMEDY™
40% Turnover
Conversion 72 72
Cat-to-Oil Ratio 6.9 6.8
Hydrogen, wt.% 0.19 0.14 Nickel Equivalent, ppm
Dry Gas, wt.% 1.8 1.6 GENESIS® LX/OlefinsMax® REMEDYTM/OlefinsMax®
Propylene, wt.% 7.4 6.4
FIGURE 13: REMEDY T M Maintains Ecat Selectivities
Propane, wt.% 1.2 1.1
Total C4=s, wt.% 8.3 7.5
IsoButane, wt.% 4.8 4.3
nC4, wt.% 1.0 0.9
LPG, wt.% 22.7 20.2
Gasoline, wt.% 43.3 46.0
LCO, wt.% 20.1 20.9
Bottoms, wt.% 7.9 7.1
Coke, wt.% 4.1 4.2
RON 92.1 92.3
MON 80.8 80.6
TABLE 4: Refiner D ACE Test Constant Conversion
Yields
GRACE DAVISON CATALAGRAM® 947.0 3.3
46.5
3.1
46.0
2.9
LCO/Bottoms Ratio
C5+ Gasoline, wt.%
45.5
45.0 2.7
44.5 2.5
44.0
2.3
43.5
2.1
43.0
42.5 1.9
42.0 1.7
41.5 1.5
64 66 68 70 72 74 76 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5
Conversion, wt.%
Coke, wt.% Feed
GENESIS®-LX REMEDYTM
FIGURE 14: Remedy Delivers Greater Gasoline Selecitivty and Deeper Bottoms Cracking
goals in tandem with unit tailored reformulation efforts allows refiner- REsolutionTM
ies to realize enhanced operations and unit profitability. ACE Ecat Data NEKTORTM (30% change-
out)
Rare earth, wt.% 3.1 2.1
Continuous development in the area of rare earth free catalysis by
Grace adds even further opportunity for overall cost savings and op- Ni + V, ppm 754 626
timization.
Cat-to-Oil, gg 4.8 5.0
Conversion, wt.% 66.0 66.0
Commercial Experience of Zero Rare Hydrogen, wt.% 0.04 0.04
Earth Catalysts Dry Gas, wt.% 1.0 1.0
Rare-earth free REsolutionTM catalysts are based on the Z-21 zeolite Propylene, wt.% 4.7 5.8
and are sourced from our manufacturing site in Worms, Germany. C4 Olefins, wt.% 6.7 7.2
REsolution™ catalysts are designed for hydrotreated and VGO ap-
LPG, wt.% 15.9 17.7
plications. Within the first six months of commercialization, the REs-
Gasoline, wt.% 46.9 45.0
olution™ catalyst has been successfully used in over seven
refineries in the EMEA region. One such application is at the MiRO LCO, wt.% 15.5 15.3
refinery in Germany. In February 2011 they switched from a catalyst Slurry, wt.% 18.5 18.7
with 3.1 wt.% rare earth to the rare-earth free REsolution™ catalyst. Coke, wt.% 1.7 1.5
ACE pilot plant Ecat testing was used to evaluate the performance
of the REsolution™ catalyst at 30% change-out. As can be seen in TABLE 5: ACE Ecat Testing of Rare-Earth Free
REsolution T M Catalyst
Table 5, conversion, dry gas yield and bottoms upgrading were simi-
lar for the REsolution™ catalyst, while delta coke was improved.
Table 5 shows a comparison of the product selectivities in more de-
tail, where the increased LPG yields (at the expense of gasoline)
can be attributed to the fact that more ZSM-5 additive was used with
the REsolution™ catalyst. The catalyst change-out has since
reached over 75%, and the RE2O3 content of the Ecat has been re-
duced from 3.1 to 0.7 wt.%. The refinery reports that the perform-
ance has not only been maintained using the rare-earth free
REsolution™ catalyst, but it has actually improved. To summarize,
MiRO has observed similar bottoms upgrading and dry gas yield, as
well as lower delta coke.
10 ISSUE No. 110 / 2011We are currently commercializing a high matrix catalyst based on
the Z-21 technology called REBEL. Two refineries have just begun
80
application of REBEL catalyst in North America. Look for an update
on commercial experience in our next Catalagram® No. 111.
79
Interpolated Standard Conversion
78
@ Constant C/O, wt.% FF
77
76
75
Commercial Experience of Low 74
Rare-Earth Catalysts for Resid Feed 73
Applications 72
71
REduceRTM catalyst based on Z-22 zeolite technology is an effective 70
0 20 40 60 80 100
means to reduce the overall rare-earth requirement in resid applica-
REduceRTM Content in Blends with Base, %
tions. Figure 15 shows the activity retention of different REduceR TM
catalyst blends with NEKTOR-ULCCTM resid catalyst as measured in
ACE pilot plant testing with 2000/3000 ppm Ni/V at constant cat-to- FIGURE 15: Activity Retention of REduceR T M
oil. Activity can be maintained at blends of up to 60% REduceR TM Catalyst Blends for Resid Applications
catalyst. It is possible to utilize more than 60% RE free catalyst in
the blend, depending upon your unit’s severity and flexibility to opti-
mize the unit conditions.
The REduceRTM catalyst has been successfully commercialized, and
is currently applied in more than 10 resid applications in Europe.
One such example is at the Bayernoil, Vohburg refinery in Germany,
which processes a resid feedstock with typical Ecat Ni+V levels of >
7,000 ppm. This refinery was previously using a NEKTORTM catalyst
that contained 3.1 wt.% RE2O3, and performed extremely well. In
April 2011, Bayernoil, Vohburg began to blend 30% of the rare-earth
free REduceRTM catalyst with the NEKTORTM catalyst and the FCCU
data is shown in Figure 16. The REduceRTM catalyst blend provides 50% NEKTORTM
NEKTORTM
50% REduceRTM
similar/better bottoms upgrading, a lower delta coke, lower regener-
ator bed temperature and increased conversion at constant feed at- Cat-to-Oil Base Base +0.4
mospheric residue content. Conversion, wt.% Base Base +0.5
Hydrogen, wt.% Base Base +0.02
The refinery considered the performance of the REduceRTM catalyst
C1+C2’s, wt.% Base Base +0.2
to be such a success that they increased the blending ratio from
30% to 50%, thus reducing the overall rare earth content of the cata- Propylene, wt.% Base Base +0.4
lyst to 1.5 wt.%. Table 6 shows the FCCU product yields obtained C4 Olefins, wt.% Base Base +0.6
with the 50% REduceRTM catalyst blend compared with the LPG, wt.% Base Base +2.0
NEKTORTM catalyst. For the purpose of evaluating the actual cata-
Gasoline, wt.% Base Base -1.6
lyst performance the yields shown are calculated on the basis of
LCO, wt.% Base Base -0.2
constant feed properties and independent operating conditions. The
key objective of the refinery was to maintain conversion and bottoms Slurry, wt.% Base Base -0.2
upgrading while reducing rare-earth content. As can be seen these Coke, wt.% Base Base -0.1
key objectives were met, and in addition conversion and bottoms up- Delta Coke, wt.% Base Base -0.09
grading were even improved. The REduceRTM catalyst provided a
similar coke yield but an improved delta coke, and allowed regenera-
CAR, MT/D Base Base
tor bed temperature to decrease by 60°F.
Ecat Ni, ppm Base Base
Ecat V, ppm Base Base
Conclusion
Regen Bed Temp, ˚C Base Base -15˚C
In response to the increasing cost and decreasing availability of
rare-earth metals, Grace Davison Refining Technologies has suc- TABLE 6: FCCU Data of the REduceR T M Catalyst Blend
at 50%
cessfully commercialized the REpLaCeRTM family of low and zero
GRACE DAVISON CATALAGRAM® 11Regenerator Bed Temperature Delta Coke (Non-Mass Balanced)
Wt.%
˚C
ROT, ˚C Apparent Conversion (non-mass balanced), wt.% FF
Apparent Conversion Slurry Yield
Wt.% FF
Wt.% FF
At Res in Feed, wt.% Conversion, wt.% FF
NEKTORTM REduceRTM
FIGURE 16: FCCU Data of the REduceR T M Catalyst Blend at 30%
rare-earth catalysts. REsolutionTM and REBELTM catalysts are based rare-earth inflation. As shown in Figure 17, the REpLaCeRTM family
on the Z-21 zeolite, while REACTOR TM and REduceR TM incorporate of catalysts have received rapid global market acceptance.
the newly developed Z-22 zeolite. Grace’s experienced Technical
Services team has successfully applied each of these technologies Through the development of proprietary non rare-earth stabilized Z-
in hydrotreated/VGO applications as well as resid operations. Alone 21 and Z-22 zeolites Grace Davison is the only catalyst supplier that
or blended with a rare-earth containing conventional catalyst, these provides zero rare-earth FCC catalysts. Grace Davison’s Technical
new FCC technologies have demonstrated excellent stability, selec- Service team is well experienced in the application of our broad port-
tivity and activity retention, which minimizes potential exposure to folio of FCC catalysts. Let Grace’s RT team help you find the opti-
mal catalyst solution for your operation.
35
30
References
25
1. China National Geographic, Issues 7-12, 1992.
Baillie, C., et.al., Hydrocarbon Engineering, March 2011, pg.
20
2.
15
33.
10
3. Schiller, R.K., et.al., “The GENESIS™ Catalyst System,” Cata-
lagram® 102, Fall 2007.
5
Sep 11
4. Schiller, R.K., et.al., “New Maximum Activity FCC Catalyst, Al-
FIGURE 17: Rapid Global Market Acceptance of the cyonTM”, NPRA 2010, AM-10-172.
REpLaCeR T M Family of Catalysts
12 ISSUE No. 110 / 2011You can also read
