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Catalyst Best Practices
Abu Dhabi International Downstream, 10-12 May 2015
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?
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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?
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Catalyst Handling
One issue for Takreer will be to handle and manage a large
amount of FCC catalyst
Local Production
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.
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 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
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Catalyst
Catalyst Handling
One issue for Takreer will be to handle and manage a large
amount of FCC catalyst
Delivery: safe, fast, dust-free
 Silo facilities allows fresh catalyst to be delivered by silo truck.
 This improves the working environment by eliminating problems of dust
with the use of super sacks.
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emissions
associated
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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.
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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 in an
environmentally friendly way?
4. What is the best selection method for optimum catalyst
technology?
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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
Bottoms Upgrading
 Grace has proposed a finely tuned resid FCC catalyst containing high zeolite
stability and metals tolerance to meet Takreer’s resid feedstock requirements.
 Grace Catalysts incorporates state of the art Vanadium trapping functionality
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 The catalyst also contains a balanced mesoporosity to achieve the optimum
level of coke-selective bottoms cracking
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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
Propylene Selectivity
Physical Properties
 The Grace catalyst is formulated to provide the appropriate level of H-transfer
activity to increase LPG olefins.
Grace proposes the additional use of the OlefinsUltra® HZ additive, which is a
patented
that provides the highest propylene activity in the market
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 Catalyst physical properties are also important, for example, Grace catalysts
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have
industry leading attrition resistance for minimum losses.
Technical Service
Grace will supply industry-leading technical service and support
Optimizing unit operation
Troubleshooting
 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.
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 Grace has introduced an independent critical review service to provide a health
check on FCC operations. This feature has been widely appreciated and has
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assisted
with shutdown planning and capital expenditure.
Technical Service
Grace will supply industry-leading technical service and support
Knowledge Sharing
 Grace provides regular on-site and off-site workshops specifically created for
FCC process engineers covering such topics as:
 feedstock properties
balance,
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mass balance
 unit optimisation and troubleshooting strategies
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Continuous Innovation in FCC Catalyst Technology
EnhanceR 4G
MIDAS® in EMEA
REpLaCeR®
Rare-earth free
FCC catalysts
High matrix
bottoms cracking
catalyst
Used in over
170 FCC’s
Used in over 120
FCC’s globally
ACHIEVE® Series
NEKTOR-4G
ResidCrackeR-4G
NADIUS-4G
ProtAgon-4G
EnhanceR
Platform
New holistic
approach to
pre
catalyst
design
REsolution
MIDAS®
REactoR
2003
REduceR
2003
ProgREss
2003
Used in over 100
FCC’s in EMEA
2011 2013
2009
2005
- 2006
2013
ACHIEVE
2011
®
2014
MIDAS® Gold
400
MIDAS® Gold
ACHIEVE® 400
20032009
1G
2G
NEKTOR
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3G
NaceR
NOMUS
NOMUS-DMAX
DieseliseR
NADIUS
ProtAgon
ResidCrackeR
Maximum octane
and butylene
selectivity
Used in 3 FCC’s
in N. America
Highest
activity, deep
conversion
resid catalyst
Used in 7
FCC’s globally
2015
Next Generation of EnhanceR Catalysts
Grace has developed 4th generation EnhanceR catalyst families,
including:
NEKTOR-4G
ResidCrackeR-4G
Nadius-4G
ProtAgon-4G
Coke selecvity
for resid feeds
Bottoms
upgrading for
resid feeds
High activity
for low metals
feeds
Propylene
Maximisation
Over 70% of all residue FCCUs in EMEA use Grace’s EnhanceR technology
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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
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?
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Sustainable Solutions
Grace recognises the importance of providing sustainable
solutions
 Grace has a permit to collect, store,
Catalyst Life Cycle Management
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
Grace’s REACH registration umbrella.
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Work with an experienced metals reclaimer
who has a track record of safely handling
hazardous waste.
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?
Click to edit text styles
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Catalyst Selection
To prepare a proper catalyst selection and
minimize risk following procedure is
highly recommended:
 Physical Testing
 To prevent severe issues in the commercial unit from
problematic attrition resistance as well as fluidisation
properties.
 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 yield
results using state of the art FCC model
 Enables comparison at constant feed rate and heat
balance
 Activity retention is considered at constant CAR
 Provides the accuracy required for unit operating and
performance changes
 Model optimisation of the operation
 To select the most economic catalyst technology
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A catalyst selection study is the only way to compare different
18 catalyst technologies on a comparable basis!
For additional information, please visit www.grace.com