GENESIS® Catalyst System

Achieve the Ultimate in FCC Catalyst Flexibility with GENESIS®

Possessing the flexibility to change catalyst formulation concurrently with perpetually changing economic drivers is essential to maximizing profitability of the FCC. GENESIS® is a multi-component blend of MIDAS® and at least one additional dissimilar catalyst. GENESIS® catalyst systems are capable of quickly responding to market dictated yield shifts.

The GENESIS® catalyst system was devised such that each catalyst component excels in a unique performancecategory. The MIDAS® component provides a high matrix input to maximize conversion of bottoms and to increase LCO yield. Depending on the requirements of the refiner, a second GENESIS® component is commonly characterized by higher zeolite content and activity to impart superb coke and gas selectivities.

Via the GENESIS® catalyst system, the Z/M ratio (and activity) are optimized to correspond with the distinctive operating conditions, constraints and feedstock of each unique unit. Periodic shifts in the catalyst system blend ratios permit the refiner to benefit from short term economic opportunities, manage changes in feedstock, seasonal changes, and counter effects from outages at other influencing units within the refinery.

The commercial data in Table 1 below illustrates yield deltas observed by a refiner that used GENESIS® to attain catalyst flexibility during the seasonal changes commonly observed throughout the year. Both formulations outperformed the competitive base technology in both modes of operation.

Table 1. Shifting Modes of Operation using GENESIS®

Competitive CatalystGENESIS®

(Max Gasoline)Relative to Base

GENESIS®

(Max LCO)Relative to Base

Gasoline, lv% Base +3.0 +1.0

LCO, lv% Base +1.5 +5.0

Bottoms, lv% Base -1.5 -2.2

Repeatedly, GENESIS® has proven to outperform the use of a single catalyst type. The expectation for many is that the performance of GENESIS® can be predicted simply by averaging the yields of each individual catalyst component. There, however, is an added benefit, beyond flexibility. A synergistic effect is generated when MIDAS® is blended with additional catalysts. This phenomenon has been observed in both the laboratory and in the field. This is demonstrated in Figure 1 on the reverse.

As exemplified in Figure 1, the performance improvement by means of GENESIS® use is clearly not a linear average. In this case, a synergy between the two catalyst components works to create an unparalleled coke to bottoms relationship when compared to other lone catalysts. Collective GENESIS® performance is proven to be greater than any single catalyst’s overall performance. Valid across a very broad range of feeds, the synergistic effect has been observed in units spanning from resid to hydrotreated feedstocks.

Figure 1. Synergistic Effect of the GENESIS® System

As illustrated in Figure 2, GENESIS® catalyst systemsoptimize the three step bottoms cracking mechanism of Zhao et. al. [NPRA 2002]. High porosity in the range of 100 to 600 Å, a signature of MIDAS®, is particularly effective for adsorbing and facilitating the coke-selective cracking of large molecules during this stage. Type II cracking, involving dealkylation and paraffin cracking, is driven by zeolite activity contributed by the second high Z/M GENESIS® blend component. The Type III mechanism involves cracking the naphthene rings of naphthenoaromatic compounds. MIDAS® selectively cracks the naphthene rings without coke and gas penalty.

The GENESIS® FCC catalyst system has beensuccessfully used in over 196 applications and, asshown in Figure 3, in more than 70 refineriesworldwide. The average user has reformulated morethan once to achieve the objectives of regularlychanging market requirements.

A fast response to changing market demands is key tomaximization of the ideal unit yields and lucrative unitoperation. There is a unique GENESIS® formulationavailable to bring your unit to a state of optimalprofitability. For further information regardingGENESIS®, please contact your Grace representative.

Figure 2. Three Step Cracking Mechanism

Figure 3. GENESIS® Market Acceptance

W. R. Grace & Co.-Conn. | 7500 Grace Drive | Columbia, MD 21044 | USA | +1.410.531.4000 | www.grace.com

The information presented herein is derived from our testing and experience. It is offered, free of charge, for your consideration, investigation and verification. Since operating conditions vary significantly, and since they are not under our control, we disclaim any and all warranties on the results which might be obtained from the use of our products. You should make no assumption that all safety or environmental protection measures are indicated or that other measures may not be required.

Version dated 08/2014