Alternatives to Rare Earth - Commercial Evaluation of REpLaCeR® FCC Catalysts at Montana Refining Company

After the sweeping reduction of Chinese export quotas, rare earth metals experienced price hyperinflation in the range of 2700% between August 2010 and July 2011. FCC catalyst has experienced unprecedented inflation as a result. Rare earth is used to stabilize FCC catalyst zeolite in order to provide high FCC catalyst activity, liquid selectivities and superior coke selectivity. Removing rare earth from FCC catalyst will provide relief in catalyst expenses; however, it is not an economical solution in most FCC operations due to a lower activity and product value.

Alternate materials and processing must be used to stabilize the FCC zeolite to ensure a profitable yield slate without rare earth. Grace has recently developed and commercialized its new REpLaCeR® family of catalysts, a portfolio of low and zero rare earth catalysts applicable to a broad range of FCC applications. Presently, over 50 units worldwide use REpLaCeR® FCC technology.

Montana Refining Company (MRC) partnered with Grace to commercialize a rare earth-free REMEDY™ catalyst from Grace’s new REpLaCeR® family of catalysts. MRC has successfully applied a zero rare earth REMEDY™ over a moderate rare earth GENESIS® FCC catalyst. Commercial results demonstrate similar unit conversion at similar catalyst additions. Coke selectivity and slurry cracking were maintained with REMEDY™ while gasoline selectivity increased.