08-08-2024

Grace advances iron tolerance in FCC catalysts, develops innovative iron deactivation protocol

W. R. Grace & Co, a leading global specialty chemicals company, today announced a new solution for treating iron contamination in the fuel refining process, based on a series of research breakthroughs. The new three-pronged approach helps mitigate iron poisoning that can result from processing more economic but heavier crude feedstocks, creating more flexibility – and more opportunity – for refiners to optimise the fluid catalytic cracking unit (FCCU).

“Traditional value drivers like efficiently processing heavy crude remain essential to the refining industry to meet persistent demand and maximize profitability,” said Luis Cirihal, President, Refining Technologies, Grace. “Our committed team of researchers and catalyst experts have made great strides in the area of iron tolerance in an FCCU, giving refiners the flexibility they need in feedstock selection.”

To address iron tolerance, the Grace research team pioneered the three-pronged approach which includes:

• Matrix Surface Area Optimisation – achieved through the base catalyst, with Grace MIDAS Pro catalysts utilising high matrix surface area (MSA) and Grace FUSION catalysts offering a balanced coke-to-bottoms selectivity profile
• Enhanced Macroporosity and Pore Size Distribution – achieved by fine-tuning the catalyst with innovative Grace MILLE technology to optimise pore structure
• Novel Catalyst Treatments – leveraging Grace’s new iron deactivation protocol, Grace-IDP, Grace can simulate iron deactivation in a lab setting, unlocking significant research potential to enhance FCC catalyst iron tolerance

A recently published whitepaper about the challenges of iron tolerance and its solutions details the Grace-IDP research. Grace will host a technical webinar on the topic on August 14 with Hydrocarbon Engineering.

“As the refining industry navigates the ongoing energy transition, strategic operators will thrive,” said Matt Kirchner, Vice President, Marketing, FCC, Grace. “FCC units, with their ability to handle diverse feedstocks—including traditional high-iron streams, biogenic feedstocks, and renewable/recycled materials – will be central to future strategies. Maximising the FCCU operating window, especially in terms of feed metals tolerance, remains essential for optimising refinery profitability.”