Breakthrough research leads to major FCC catalyst iron tolerance advancements

As the refining industry navigates the ongoing energy transition, strategic operators will thrive. 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.

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In recent years, iron tolerance has emerged as a significant challenge for catalyst suppliers, researchers, process licensors, and refinery operators. This white paper outlines how Grace’s research team pioneered a three-pronged approach to address iron tolerance:

Matrix surface area optimisation: Grace’s broad portfolio offers solutions tailored for FCCUs processing high iron feeds. MIDAS® Pro catalysts employ high MSA, and FUSION^® catalysts offer a balanced coke to bottoms selectivity profile while enhancing iron tolerance.
Enhanced macroporosity and pore size distribution: by fine-tuning the pore structure of its catalyst, Grace has improved its ability to withstand iron contamination. The innovative MILLE^TM technology optimises the pore structure for maximum feed iron tolerance.
Novel catalyst treatments: the innovative Grace-IDP is a game-changer. Through meticulous laboratory simulations, Grace has developed a protocol that effectively simulates iron deactivation, unlocking significant research potential and exploration of novel treatments to enhance FCC catalyst iron tolerance.

When combined, these R&D advances empower refiners to respond swiftly to iron-related challenges. They also enable greater flexibility in feedstock selection, ultimately leading to increased profitability. Grace’s commitment to innovation positions the company as a key player in the evolving energy landscape.

Download this white paper to find out more.