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Aerial shot of Grace's Curtis Bay works. (Image source: Grace)

W. R. Grace & Co. (Grace), a leading global specialty chemicals company, has announced a groundbreaking advancement in iron tolerance for fluid catalytic cracking (FCC) catalysts

In the dynamic world of fluid catalytic cracking (FCC), traditional value drivers such as feedstock flexibility remain crucial for most transportation fuel refiners. However, iron tolerance has emerged as a significant challenge for catalyst suppliers, researchers, process licensors, and refinery operators. Grace’s research team recently pioneered a three-pronged approach to address iron tolerance which includes:

  • Matrix surface area optimisation: Grace’s portfolio includes tailored solutions for FCCUs processing high-iron feeds. MIDAS® Pro catalysts utilize high matrix surface area (MSA), while FUSION® catalysts offer a balanced coke-to-bottoms selectivity profile, enhancing iron tolerance.
  • Enhanced macroporosity and pore size distribution: Fine-tuning the pore structure improves its ability to withstand iron contamination. Innovative Grace MILLE™ technology optimises pore structure for maximum feed iron tolerance.
  • Novel catalyst treatments: A game-changing Grace-IDP protocol simulates iron deactivation in the lab. This unlocks significant research potential to explore novel treatments for enhancing FCC catalyst iron tolerance.

Responding to iron-related challenges

“These R&D advances empower refiners to respond swiftly to iron-related challenges, enabling greater flexibility in feedstock selection and ultimately leading to increased profitability,” said Luis Cirihal, president, Grace Refining Technologies. “Grace’s commitment to innovation positions us to influence the evolving energy landscape.”

Grace recently published a detailed whitepaper about the challenge of iron tolerance and its solutions and will host a technical webinar on the topic on August 14, 2024 with Hydrocarbon Engineering.

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. Maximizing the FCCU operating window, especially in terms of feed metals tolerance, remains essential for optimizing refinery profitability.

Visit our website to learn more about Grace’s refining catalysts and additives.

PVDF is highly suitable for injecting CO2 offshore, both in depleted gas fields and aquifers. (Image source: Strohm)

Strohm, a leading thermoplastic composite pipe company, has added jumpers and flowlines for CCS applications to its portfolio, having successfully qualified its first product based on carbon fibre and advanced PVDF polymer

PVDF is a high performance polymer with a 30-year design life and a proven smaller carbon footprint compared to steel. Offering total corrosion resistance, it is highly suitable for injecting CO2 offshore, both in depleted gas fields and aquifers. With a long track-record in oil and gas, PVDF also has a very high chemical resistance and higher temperature capability.

Potential to withstand high temperatures and pressures

It is also strong enough to withstand the high temperatures and high pressures associated with ultra-deepwater hydrocarbon production, and provides a high level of natural insulation. As well as its potential for CCS applications, Strohm’s new TCP product could also revolutionise the deepwater flowline and riser market in the offshore energy industry.

Martin van Onna, Strohm CEO, said, “This is a hugely momentous breakthrough for the company, one that has been a long time coming. It has taken us more than 15 years, a lot of hard work and a huge amount of testing to get to a place where we are now able to offer a TCP product based on carbon fibre and PVDF.

“There is a big future for this innovative solution, both in CCS and in conventional offshore energy, and we look forward to working with companies to help them realise the value that TCP can bring to their projects.”

Bandlock2 closures are now available in diameters in excess of 100 inches (254cm). (Image source: Celeros Flow)

Celeros Flow Technology has up-scaled its Bandlock2 quick-opening closures so they can be incorporated on very large diameter pressure vessels and pipelines

The need for larger diameter closures is being driven by the fact that pipelines and pressure vessels are getting bigger, as a result of the growing global demand for essential products such as water, gas and oil. Available in diameters up to 100 inches (254cm), the larger diameter Bandlock2 closures offer customers the potential to reduce the number of pressure vessels and associated pipework required for any given application.

Same quick-opening mechanism

Manufactured by Celeros FT brand GD Engineering, very large diameter Bandlock2 closures offer the same proven quick-opening mechanism and sealing design as standard diameter closures. Full access is still achievable in less than a minute. They feature a unique, self-energising lip seal with integral anti-extrusion spring and offer full vacuum capability.

A hand-operated pressure warning screw assures safe operation. This is integrated into the closure mechanism and prevents the door from being unlocked until it is confirmed that the vessel’s internal pressure has been relieved. Additional secondary safety features, such as mechanical key interlocks, can be fitted and integrated with control valve operations. In addition, the locking band can be seen at all times, which satisfies design code requirements and means that the operator can actually see that the door is securely closed and locked.

The new Redline+ Packing sealing system features new materials and enhanced geometry to optimise performance. (Image source: GDEP)

GD Energy Products (GDEP), solutions provider for the frac, drilling and well servicing market, has launched its new Redline+ Packing sealing system featuring new materials and enhanced geometry to optimise performance in the harshest of hydraulic fracturing environments

Proven in the field to deliver longer life and reduced downtime, Redline+ Packing has demonstrated a significant improvement in packing performance life over GDEP’s standard Redline Packing. The patent-pending geometry improves sand exclusion and includes fortified materials guaranteed to reduce the risk of packing bore wash. Redline+ Packing also features a refined material makeup, delivering longer product life and increased heat and abrasion resistance in high-pressure environments.

Strong performance in challenging environments

In the most challenging basins, Redline+ Packing pumped over 160 million pounds of sand prior to failure, while also reducing operational downtime. During a 12-week field trial in the Haynesville Basin at pressures up to 12,500 PSI, Redline+ Packing increased performance life on average by more than two times over standard Redline and extended maintenance intervals by 45%.

Jim Yanus, engineering director, GDEP, said, “Redline+ Packing is GDEP’s latest addition to our Redline Series Consumables and was established in collaboration with our customers to deliver an even higher level of performance and consistency to their operations. Field trials have proven an increase in life expectancy and endurance across any condition in the field.”

Redline+ Packing is available for both GDEP and competitor frac fluid end designs.

The new technology uses infused microbubbles. (Image source: APS)

Adaptive Process Solutions (APS), a produced water treatment specialist, has completed a successful field trial of its new Microbubble Infusion Unit (MiFU) technology, which reduces oil in water (OiW) levels

Increased oil in water (OiW) levels in produced water are proving a challenge for operators. The new technology, designed as a retrofittable add-on to existing water treatment systems,was shown to achieve a near five-fold reduction in OiW levels in combination with a synergistic production chemical in the trial, conducted on an FPSO in the North Sea.

Infused micro bubbles

MiFU uses infused micro bubbles which attach to very minute particles of oil and fine solids in the produced water which can then be easily removed by the asset’s existing separator process. While underlying technologies have already been proven, MiFU is unique through its implementation of a patented multi-pass process which directly injects size and quantity-controlled gas microbubbles into target points in a contaminated water stream.

MiFU’s superior bubble saturation and variable bubble size range means it is capable of processing between 1,000 and 100,000 barrels of water a day, reducing up to 90% of oil and contaminants and eliminating the requirement for further costly downstream filtration and material management.

Paul McAlister, managing director of APS, said the MiFU was developed to address the industry-wide issue faced by operators to efficiently and effectively clean produced water so that it meets strict regulatory standards before it can be discharged back into the sea.

“This successful field trial is the culmination of four years’ research and development and MiFU is the first of its kind worldwide. We are a homegrown Aberdeen company and we have now launched a world-leading environmental technology,” he said.

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