8 - 10 September 2026 Buenos Aires, Argentina
The Must-Attend Refining and Petrochemical Event in Latin America
Official newspaper published by PTQ, Digital Refining, Decarbonisation Technology
inside
LARTC has truly become a community, one where we are open to knowledge-sharing and helping each other solve the problems of today and identify the opportunities of tomorrow. In 2026, we are proud to welcome a record number of attendees, a record number of speakers from a record number of countries and the largest networking programme and exhibition we have ever had in the region. Over the next few days, our agenda, curated by the World Refining Association team in collaboration with our Advisory Board, will cover key industry topics such as energy efficiency, sustainable fuels, the digi- tal revolution and AI, industry collaboration, regulatory frameworks, and much more. We are grateful to the more than 150 companies that submitted their technical abstracts for this year, and we look forward to hearing from the experts at the forefront of technological advancement across our several streams of content. atile markets is becoming a defining differ- entiator for refiners in the region. Achieving this depends on a combination of techno- logical and operational innovation, adaptive catalyst use, dynamic scheduling, predictive modelling, and disciplined turnaround plan- ning. The conversation also stressed that flexibility cannot be bought off the shelf: standardised ‘packaged’ technology solu- tions were flagged as insufficient. For flex- ibility to translate into real advantage, tools and procedures need to be tailored to each refinery’s operational realities, with strong collaboration between internal teams and external technology providers. AI in refining: from hype to value creation Artificial intelligence (AI) was recognised as having genuine transformative potential. However, the board was candid that pilot projects frequently fail without clear busi- ness alignment and realistic expectations. Members converged on several lessons for successful deployment: defining use cases tied to measurable ROI, adopting human- in-the-loop ’cointelligence’ approaches rather than full automation, and prioritising high-impact applications such as predictive maintenance, blending optimisation, and scenario modelling. Democratising access to digital tools, ensuring they serve opera- tors and planners, not just data scientists, was seen as essential. The consensus was that AI delivers value only when embedded within a broader digital masterplan linked to safety, efficiency, and strategic objectives.
Hello, and welcome to the 15th Annual Edition of the Latin American Refining Technology Conference (LARTC). We are privileged to be host- ing this year’s LARTC in
We are also glad to welcome Paul Mason and the whole PTQ team, with whom we are delighted to continue our global partner- ship. PTQ ’s collaboration with key indus- try figures and its continued dedication to producing world-class content covering our industry are very much appreciated, and we are grateful for its continued partnership across the global portfolio of World Refining Association events. Finally, thank you to everyone joining us here in Buenos Aires this week. We are pleased to welcome you, and we hope the next few days are full of new contacts, catching up with industry peers, world- class content, and key reflections on the Latin American downstream sector in 2026 and beyond. Enjoy the next few days.
Latin America downstream: Structural advantage and the investment window Co-processing SAF: Why catalyst choice is crucial for refineries FUSION catalyst: The best of both worlds
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the beautiful and historic city of Buenos Aires, Argentina, with the support of our Host Partner, YPF. We have enjoyed years of collaboration with YPF, whose vision and standing in the region make them a global reference. A sincere thank you goes to the CEO and President of YPF, Horacio Marín, as well as to Mauricio Martín and the YPF refining team, for their continued partnership with the World Refining Association. I would like to express particular grati- tude to our Advisory Board, made up of the industry’s leaders in Latin American Downstream, for their continued loyalty, support, and input to this important event.
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Energy efficiency starts with selectivity: The Prime-G+ ® advantage 9
Data-driven fired heater performance recovery
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Matt Maginnis Global Managing Director World Refining Association
Operational transformation through digital production accounting at YPF 13
Executive Board summary The LARTC 2026 Advisory Board Meeting convened ahead of the conference to deter- mine the key challenges and opportunities facing Latin American refining. The discus- sion focused on five strategic pillars essen- tial for navigating the region’s evolving downstream landscape:
SAF and low-carbon fuels: opportunity, mandate, or economic dilemma Sustainable aviation fuel (SAF) emerged as a topic of both opportunity and tension. Co-processing renewable feedstocks within existing refinery units was identified as the most pragmatic near-term pathway, offering lower capital intensity than greenfield pro- duction. Brazil’s regulatory mandate requir- ing airlines to incorporate SAF by 2027 was cited as a key driver of near-term demand, though feedstock availability, inconsistent certification standards across markets, and weak price signals continue to raise ques- tions about who ultimately bears the addi- tional cost. The board agreed that scaling low-carbon solutions will require closer col- laboration across the value chain. Culture, capability, and strategic agility Running through every theme was a shared recognition that technology and capital alone will not determine competitiveness. Skills, digital literacy, and generational workforce transitions were cited as critical success factors, alongside governance frameworks strong enough to support sustainable trans- formation. Process safety and reliability remain non-negotiable foundations. The choices refiners make now will shape which companies emerge as competitive and resilient leaders within Latin American refining. LARTC 2026 will build directly on these discussions, providing a platform for the region’s downstream community to translate this year’s insights into action.
Hydroprocessing catalyst and process synergies: Enhancing performance, reliability, and margin 15 Precious metals catalyst: Managing and maximising your asset value 19
Investment decisions for efficiency and value capture Capital constraints remain a defining fea- ture of refining in Latin America, and the board was clear that large, mutually exclu- sive investments demand rigorous prioriti- sation. A ‘back to basics’ mindset emerged as a central theme, optimising energy use, reducing losses, and standardising opera- tional excellence rather than chasing large- scale transformation projects. It was argued that this discipline not only protects margins but delivers decarbonisation as a natural byproduct of improved efficiency. Frontline- driven initiatives, described by some mem- bers as ‘performance pop-ups,’ were cited as practical tools for empowering operators to identify and act on optimisation oppor- tunities. Workforce planning was raised as an equally critical input, with capital alloca- tion decisions needing to account for talent readiness alongside technical and financial feasibility. Operational flexibility as a competitive advantage Members agreed that the ability to adjust production slates quickly in response to vol-
Capturing crude flexibility opportunities through smarter fired heater monitoring 21 Biofuels help LATAM refiners navigate geopolitical crisis from Middle East conflict 23 Mitigating fouling in a DCU sponge absorber 24
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30 November - 3 December | Madrid, Spain
THE LEADING DOWNSTREAM EVENT FOR REFINING AND PETROCHEMICAL LEADERS
Four days of valuable insight, inspiration, and collaboration to help future-proof refining’s role in the long-term energy mix.
INTRODUCING SPEAKERS FOR ERTC 2026
WHAT TO EXPECT FROM ERTC 2026
1200+ downstream business leaders in one place
Luis Cabra EMD Energy Transition & Deputy CEO, & President, FuelsEurope & Concawe
Paul Fursey Vice President & UK Lead Executive, Phillips66 & Board Director, Fuels Industry UK
Jose L. Mesa VP, Refining, Terminals & Pipelines
12 specialised technical streams , across 3 fully themed days of content
Hear form Industry leaders at Repsol, Moeve, Galp, OMV & more
Using a double opt-in system, meet relevant industry peers for focused and meaningful discussions
Elise H. Nowee President
Adrian Szkudlarski President & CEO
Tracy Hughes VP & General Manager, Refining
The ERTC Industry Awards and The Rising Star Award is back!
SCAN THE QR for more information and to secure your ticket
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LARTC 2026
Latin America downstream: Structural advantage and the investment window
Alan Gelder and Rodrigo Jacob wood mackenzie
Even as the global refinery system faces headwinds in the early 2030s from the energy transition delivering peak oil demand, Latin American refineries con- tinue to benefit from a structurally advan- taged market position. Refiners across the region typically access domestically pro- duced crude at export parity prices, while refined product markets – where most countries remain net importers – are priced at import parity. This pricing dynamic cre- ates a structural margin premium, allowing the most competitive Latin American refin- eries to achieve margins broadly compara- ble with those of top-tier global benchmark refineries, as shown in Figure 1 from Wood Mackenzie’s Refinery Evaluation Model. Looking to the future, both sides of this structural equation face pressures that will increasingly shape refinery financial performance. On the crude supply side, declining domestic production represents a growing challenge. Colombia, Ecuador, and Chile face the most acute exposure, where mature field decline could erode the crude cost advantage. Brazil’s production is expected to expand over the next dec- ade before entering decline, with the more immediate concern centred on manag- ing Brazilian export volumes. In Argentina, Vaca Muerta is expected to drive signifi- cant light tight oil production growth, chal- lenging the refining system, which typically processes medium-quality crudes. On the product side, import parity pric- ing support is expected to remain broadly intact through the medium term. While vehicle electrification and efficiency improvements are reshaping fuel demand globally, Latin America’s adoption curve significantly lags developed markets. Biofuel mandates will increasingly displace conventional fuel volumes in select mar- kets – most notably Brazil. Limited capac- ity additions are anticipated, so the region is not expected to shift from a net refined product importing position before 2040, as illustrated in Figure 2 . Brazil Brazil remains the region’s most active market for refining, biofuels, and energy transition investment. Petrobras is advanc- ing a broad portfolio of projects to expand domestic refining capacity and improve product quality, including the restart of Abreu e Lima Refinery’s (RNEST) sec- ond train, system-wide upgrades, and the development of the Boaventura Energy Complex to capture value from Brazil’s growing oil products demand. The refining industry is also positioning itself to exploit Brazil’s structural advan- tage as one of the world’s largest sup- pliers of agricultural commodities and biofeedstocks. While the Fuel of the Future programme reinforces the country’s estab- lished biofuels framework, direct benefits to oil refining remain limited. Investment opportunities are therefore also oriented
may ultimately need to source medium and heavy crude imports to maintain optimal operations, marking a structural shift for a market that has historically been self- sufficient in crude supply. Domestic crude pricing policies will have a critical bearing on refinery investments. Venezuela Venezuela was once among Latin America’s most significant refining hubs. Today, its three remaining active facilities – Amuay, Cardon, and Puerto La Cruz – operate at persistently low utilisation rates, reflect- ing years of underinvestment and infra- structure deterioration. Despite ongoing geopolitical uncertainty, our base case anticipates that these assets could undergo operational revamps and a phased ramp-up in crude throughput, con- ditional on gaining access to spare parts and technical toolkits. With naphtha and diluents supply restored, crude producers would no longer need to use domestically produced light crude as a diluent, allowing those barrels to be redirected to refinery feedstock and supporting higher through- put and improved product yields. Conclusion This combination of sustained structural margin support and a lagging energy tran- sition creates a window of investment opportunity for regional refineries – one that exists before global margins begin to move structurally lower as the transi- tion accelerates globally. Refineries posi- tioned to capture incremental throughput, upgrade crude processing flexibility, and lock in cost-advantaged feedstock access stand to derive the greatest benefit from this window. Refiners are evaluating measures to reduce Scope 1 and Scope 2 emissions through the electrification of process units and utilities, and the replacement of natural gas with biomethane for steam generation, process heating, and hydrogen production
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Figure 1 Individual refinery net cash margin benchmark across Americas from WM Refinery Evaluation Model (2024)
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Figure 2 Country gasoline, jet, and diesel/gasoil combined balances from Product Market Service Strategic Outlook 2026
emerge as one of the most attractive export destinations for Brazilian low-carbon fuels, alongside the marine fuels sector. By con- trast, recent US policy developments have been increasingly designed to support domestic production and limit reliance on imported feedstocks and fuels. Argentina The ongoing expansion of light tight oil pro- duction from Vaca Muerta will have direct implications for Argentina’s downstream sector. As volumes grow, investment deci- sions are likely to consolidate around securing access to lighter crude streams, alongside targeted refinery upgrades – including condensate splitters and addi- tional crude distillation units – to optimise processing of the evolving crude slate. On the demand side, broader economic recovery could support a gradual increase in domestic fuel consumption. Argentina’s vehicle fleet remains one of the least elec- trified in the region, underpinning contin- ued reliance on conventional transport fuels. The primary downside risk centres on the natural decline of heavy crude pro- duction from mature fields, which could constrain throughput at refineries config- ured to process heavier grades. As Vaca Muerta continues to increase exports of lighter crude, these refineries
towards export markets, driven by rising global demand for low-carbon and renew- able fuels. This opportunity is particularly relevant for projects processing feedstocks that comply with increasingly stringent inter- national sustainability requirements. In Europe, RED III implementation is rein- forcing the distinction between feedstock pathways, placing greater restrictions on food-based crops and increasing scrutiny on indirect land-use change. Sustainability criteria and feedstock eligibility require- ments are expected to tighten further over the coming decade. Decarbonisation of operations – and consequently the final carbon impact of finished products – is also a target invest- ment area. Refiners are evaluating meas- ures to reduce Scope 1 and Scope 2 emissions through the electrification of process units and utilities, and the replace- ment of natural gas with biomethane for steam generation, process heating, and hydrogen production. Such initiatives could materially reduce operational carbon intensity while leveraging Brazil’s low-car- bon power grid and emerging biomethane industry and regulatory framework, help- ing companies achieve their decarbonisa- tion ambitions. Under this framework, Europe is likely to
Contact: Rodrigo.Jacob@woodmac.com
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LARTC 2026
Co-processing SAF: Why catalyst choice is crucial for refineries
Miguel Angel Antonio Tutera and Ignacio Costa TOPSOE
Across Latin America, co-processing has emerged as an attractive entry pathway for refineries looking to enter sustainable avia- tion fuel (SAF) production without immedi- ately committing to the higher Capex of a dedicated renewable unit. By blending renew- able feedstocks into existing hydrotreaters or hydrocrackers alongside conventional fossil streams, refiners can begin producing SAF within months rather than years. This proposition has made co-process- ing one of the fastest-growing entry points into renewable fuels in the region. In Latin America, Topsoe is currently working with multiple refineries in different countries on tailored catalyst systems to produce renew- able fuels – among them a project that, in Q4 2026, is expected to become one of the world’s first references for SAF co-process- ing at 5%. This underscores both the com- mercial momentum behind this pathway and the technical readiness required to exe- cute it reliably. Why co-processing, and why now? Co-processing allows refiners to blend renewable materials – such as vegetable oils, animal fats, and used cooking oil – into an existing unit alongside fossil feed, rather than building or repurposing a facility dedi- cated exclusively to renewables. The appeal is straightforward: minimal capital invest- ment, fast implementation, and the flexibil- ity to adjust renewable content in response to market demand or regulatory pressure. For refiners across Latin America exam- ining emerging SAF mandates and look- ing to diversify revenue through renewable fuel, co-processing offers a pragmatic, de- risked way to participate in the SAF market while preserving the option to scale further or move to a dedicated unit later. Under ASTM D1655, co-processing of renewable esters and fatty acids into jet fuel is capped at 5% by volume, with a separate pathway allowing hydroprocessed renewa- ble hydrocarbons to be co-processed or co- fractionated at up to 24% of feed and 10% of product. These regulatory ceilings mean co-processing will not replace dedicated renewable fuel production for refiners tar- geting high-volume SAF output. However, for the initial phase of blending mandates now taking effect globally, it is the fastest and most capital-efficient route to a compli- ant product. Different production demands Blending even a modest volume of renew- able feedstock into a conventional hydro- treater changes the processes inside the unit in ways that matter. Renewable feeds require substantially more hydrogen to strip out oxygen through hydrodeoxygenation, and the reaction is highly exothermic. The resulting higher exotherms in the reactors need to be managed carefully to protect catalyst and equipment. Deoxygenation also produces significant water, which must be handled to avoid corrosion in down-
Topsoe is working with multiple refineries globally on tailored catalyst systems to produce renewable fuels including SAF
imise intermediate-product quality, with medium HDO activity and high double-bond saturation that helps limit coking and safe- guards against pressure drop. TK-3002 and TK-3003 round out the main-bed chemistry, with TK-3001 offering improved HDO selectivity, higher activity, reduced coking, and greater metals tolerance. Taken together, the system combines dedicated contaminant capture at the top of the bed with downstream HDO functionality, help- ing refiners manage both catalyst protec- tion and stable reactor hydraulics under the more demanding conditions created by renewable feeds. Since the series is designed to operate via the hydrogenation route rather than decar- boxylation, oxygen reacts primarily as water rather than CO2. This improves yield signifi- cantly, while also reducing the need to purge the CO2 and simplifying downstream han- dling by avoiding a large CO2 load through the high-pressure loop. Where deep dewaxing is needed to meet freezing point specifica- tion, the series is complemented by Topsoe’s TK-930 D-Wax catalyst, which has industry- wide recognition for its performance and is deployed across multiple commercial sites following strong pilot-scale results. Together, this catalyst system is built to deliver longer, steadier cycle lengths under the specific, more complex conditions of co-processing: higher hydrogen demand, elevated exotherms, increased water for- mation, and a contaminant profile that dif- fers meaningfully from straight fossil feed. For refiners, the practical outcome is a unit that can sustain its target blending ratio over a full cycle without the pressure drop esca- lation or premature catalyst deactivation that renewable feedstocks can otherwise introduce. This reflects a broader Topsoe approach to reactor grading and contami- nant control that has evolved over more than five decades, from basic inert void fillers to fully engineered filtration and guard systems developed to address fouling and contami- nation challenges in commercial operation.
stream equipment. Contaminants carried in with the renewable feedstock, phosphorus in particular, can accelerate catalyst fouling and shorten cycle length if the catalyst sys- tem is not designed to capture them. More broadly, renewable feeds can introduce a multi-contaminant profile, and maintaining low pressure drop through the guard sec- tion becomes an important part of preserv- ing stable unit operation over the full cycle. Jet fuel specifications add a further layer of difficulty. Freezing point is one of the most demanding parameters in ASTM D1655, and meeting it requires convert- ing the straight-chain n-paraffins produced during deoxygenation of renewable feed- stocks into branched i-paraffins through deep dewaxing, without over-cracking the renewable molecules out of the jet fraction. Getting this balance right, while maintain- ing stable pressure drop and a commer- cially viable cycle length, is what separates a well-executed co-processing project from one that struggles to hit target run lengths. TK-300X series as an enabler Topsoe’s TK-300X series – the third-gen- eration hydrodeoxygenation (HDO) cata- lyst family comprising TK-3001, TK-3002, and TK-3003, together with the TK-3000 PhosTrap™ guard catalyst – was developed to address exactly this set of challenges. In co-processing service, the graded HDO cat- alysts are loaded on top of the existing fossil catalyst, with loading ratios calibrated to the target blending percentage so that the cycle length of this HDO catalyst matches the cat- alyst loaded for the fossil service beneath it. TK-3000 PhosTrap sits at the top of the bed and is designed to capture phosphorus and other contaminants before they reach the main catalyst, using a pore structure that allows deeper diffusion into the pellet and picks up four to six times more phos- phorus by volume than the previous genera- tion of guard catalyst. TK-3001 sits downstream of the PhosTrap guard and is designed to max-
did you know? Topsoe’s catalyst system is built to
What this means for refiners entering the market For a refinery evaluating co-processing as an entry point into SAF, the unit-level modifica- tions required are typically limited to cata- lyst change-out, along with adjustments to hydrogen supply, water separation, and cor- rosion protection. These are changes that are manageable without major capital invest- ment, particularly at blending ratios up to 5%. Choosing a catalyst system engineered specifically for co-processing conditions, rather than adapting one designed for stan- dalone renewable service, is what determines whether that investment translates into a unit that reliably hits its production and cycle- length targets from the first run onward. Topsoe has supported renewable fuel pro- duction since 2004, and roughly a third of SAF produced globally today uses its tech- nology. As co-processing continues to gain traction across Latin America as a fast, capital-light route into SAF production, the TK-300X series and Topsoe’s experience can help refiners in the region make that transi- tion with the operational stability and know- how their investment case depends on. Contact: Miguel Angel Antonio Tutera, MITU@topsoe.com and Ignacio Costa, IFCO@topsoe.com deliver longer, steadier cycle lengths under the specific, more complex conditions of co-processing
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START YOUR SAF JOURNEY NOW BY CO-PROCESSING RENEWABLE FEEDSTOCKS
Sustainable Aviation Fuel (SAF) is crucial for bringing down the CO 2 emissions of the aviation industry. Co-processing is a quick and cost-effective pathway to SAF production without major modifications to your refinery. By adding renewable feedstocks in your existing kerosene hydrotreater, you’re ready for takeoff on your SAF journey tomorrow .
Get the full details on topsoe.com/co-processing/kerosene-hydrotreating
LARTC 2026
FUSION catalyst: The best of both worlds
Akash Pahuja and Michael Hawkins W. R. Grace & Co.
FUSION ® catalyst is one of the latest FCC catalyst families from W.R. Grace & Co. (Grace), designed to deliver superior coke- to-bottoms performance and higher value product yields across a range of feed pro- files. Its advanced matrix binding system allows for the integration of proven technol- ogies for first-rate coke selectivity, metals passivation, and bottoms cracking perfor- mance into a single-particle solution. This novel technology was a finalist for the 2021 Hydrocarbon Processing Best Catalyst Technology Award and has since been used successfully in more than 35 commercial units around the world. For Latin American refiners facing pres- sure to optimise profitability, increase feed flexibility, and process heavier, higher- metal feedstocks, FUSION catalyst offers a proven approach to improving FCC unit performance while maintaining operational flexibility. The catalyst builds on more than a dec- ade of Grace laboratory and commercial experience with blended catalyst systems, integrating the same core benefits into one solution. This new technology increases the functional qualities of Grace’s integral vana- dium trap (IVT), low coke matrix (LCM) Ni passivation, and bottoms cracking matrix (made popular in its MIDAS ® platform). The result is a catalyst that can help refin- ers process heavier, higher-metal feeds, gain flexibility to increase FCC feed rates, or move to higher conversion and product yield targets without significantly increas- ing fresh catalyst addition rates. Unique Approach to Catalyst Design The FUSION catalyst advanced matrix binding system deploys Grace technolo- gies for intrinsic bottoms cracking and met- als trapping into a single catalyst particle. This reduces diffusion path length versus alternative catalyst systems or separate- particle metals traps. Improved diffusion of heavy feed components supports pre- cracking of large molecules and, when combined with advanced metals trapping, delivers premium coke-selective bottoms cracking. FUSION maintains traditional mesoporo- sity in the 100 to 600 Å range while pro- viding higher pore volume in the >1,000 Å macropore range. These larger pores allow heavy feed molecules to diffuse more effec- tively into the catalyst, reach active sites, and undergo cracking reactions. This pore structure supports one of the catalyst’s important benefits: improved bottoms cracking. The pore-size distribution of FUSION is shown in Figure 1 and indicates higher macroporosity while maintaining mesopo- rosity for bottoms cracking and coke selec- tivity. The advantages of the catalyst have been demonstrated across a range of refin- ery configurations and operating objec- tives. The following case studies illustrate how refiners have used the technology to improve conversion, increase flexibility, reduce operating costs, and unlock addi- tional value from challenging feedstocks.
heavier material into marketable products. These gains were achieved despite signifi- cantly lower catalyst additions. These improvements were driven by the catalyst’s matrix architecture and metals management technologies. The catalyst supported deeper partial-burn operation, higher catalyst-to-oil ratios, and lower regenerator temperatures, while its diffu- sional properties improved access to active sites during heavier feed processing. Conclusions Through manufacturing and processing advancements, Grace has combined high Z/M coke selectivity and low Z/M bottoms upgrading into a single solution: FUSION catalyst. Its functional materials interact within one particle to deliver improved per- formance versus historical catalyst systems. The catalyst increases the functional qualities of Grace’s integral vanadium trap, low-coke matrix nickel passivation, and MIDAS-based bottoms-cracking matrix. It contains optimised, uniformly distributed metals-trapping and matrix functions with- out sacrificing physical properties. For Latin American refiners needing to process heavier feedstocks, improve product selectivity, increase operational flexibility, and enhance refinery econom- ics, FUSION catalyst provides a proven, commercial solution. With demonstrated success across a variety of operating envi- ronments, it offers refiners a tool to cap- ture more value from their FCC operations as market demands continue to evolve. DID you know? FUSION catalyst offers a proven approach • Excellent coke selectivity and bot- toms cracking performance in a single particle with optimised porosity and an innovative catalyst binding system. • Increases the functional qualities of Grace’s IVT, LCM Ni passivation, and bottoms cracking matrix to deliver enhanced performance. • Enables the processing of cost- attractive heavier feedstocks with higher metal levels without significantly increasing fresh catalyst addition rate. Benefits of FUSION Catalyst Advanced Matrix Binding System to improving FCC unit performance while maintaining operational flexibility
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Figure 1 Hg-pore size distribution of the novel single particle FUSION vs traditional cata- lyst systems
Realised goals
FCC unit objectives
Minimise the main column bottom yield Increase LCO/HCN yield Decrease delta coke to process either more carbon or more feed Maintaining/increasing propylene and butylenes yields Maintaining/increasing RON
Increase unit conversion Enable use of economic low-quality feed Increase high - value products $0.55–$1.17/bbl value delivered
FUSION coke selectivity and bottoms cracking in a single particle outperformed competitive technologies
Figure 2 Summary of recent FUSION commercial trials
Case Study 1 This trial involved an FCC unit that had used Grace technologies for more than 25 years before conducting back-to-back com- mercial trials against two competitors. The unit processed significant resid, with typi- cal feed concarbon of 3.9 wt% and Ecat Ni + V of 5,500 mg/kg. FUSION catalyst met the trial objectives of improved conversion, greater feed flexibility, and better product selectivity, unlocking an estimated $0.55- $1.17 per barrel of additional value depend- ing on operating mode and product prices. Case Study 2 A FUSION catalyst trial began at a large North American refiner in late May 2025 and reached 70% turnover by mid-June. The catalyst delivered measurable value in three categories: lower operating expense, greater operational flexibility, and improved product yields. Fresh catalyst addition rates were
reduced by 0.35 lb/bbl, generating more than $5 million in annual savings. Antimony usage also declined because of supe- rior nickel passivation, saving an addi- tional $400,000 per year. The unit gained deeper partial-burn capability, enabling higher conversion or heavier feed process- ing. Yield improvements included a ~1.5 vol% increase in gasoline and diesel and a ~1.5 vol% reduction in slurry. Total value uplift was calculated at ~$0.58/bbl, or more than $14 million per year. The reduction of more than 20% in fresh catalyst addition rate was a key outcome for the unit ( Figure 3 ), especially as this reduction was achieved without degrading unit performance. FUSION improved the FCC unit’s yield pro- file and increased higher-value liquid produc- tion from challenging resid feedstocks. The most valuable shifts were the gasoline and diesel yield increase and slurry yield reduc- tion, indicating more effective conversion of
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Contact: Akash.Pahuja@grace.com Michael.Hawkins@grace.com
Figure 3 Catalyst addition rate
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Go Heavy!
Process heavier FCC feedstocks without compromise. Grace’s FUSION ® catalyst technology transforms heavy resid
operations. It’s built on a breakthrough process platform and a proprietary matrix binding system that fuses two of Grace’s most advanced technologies into a single-particle powerhouse. FUSION ® delivers unmatched coke selectivity and bottoms-cracking performance, enabling refiners to run heavier, higher-metal feedstocks without added catalyst or circulation bottlenecks. Proven in the Field Units running FUSION ® operate with Ecat metals levels exceeding 12,000 ppm Ni+V. Talk to your Grace representative to learn how FUSION ® can handle your heaviest feedstocks.
grace.com
LARTC 2026
Energy efficiency starts with selectivity: The Prime-G+ ® advantage
Arnaud Cotte axens
Producing cleaner transportation fuels is not only a regulatory requirement; it is a societal commitment. For refiners, deliver- ing ultra low sulphur gasoline must not come at the expense of the product’s intrinsic value, i.e. octane. Yet, conventional desul- phurisation approaches penalise octane by saturating olefins, forcing refiners to com- pensate through more expensive blending components and higher energy pathways. In tight and volatile markets, octane loss rapidly becomes a margin issue. This is where Axens’ Prime G+ ® , selective FCC gasoline desulphurisation technol- ogy, has emerged as a global reference for addressing this trade-off, combining deep desulphurisation with excellent octane retention and strong environmental perfor- mance. With more than 300 commercial references worldwide, Prime G+ is widely recognised as the benchmark technology representing around 70% of the global installed market and capturing a near-dom- inant share of new deployments. In South America, the majority of FCC gasoline pro- duction is treated using a Prime G+ scheme and/or Prime G+ catalyst family, demon- strating local confidence, economic superi- ority, and operational robustness. Looking forward, ensuring the long-term sustainability of refining operations requires continuous innovation focused on the two most powerful contributors to profitability: value retention (octane) and lower operating costs through reduced energy demand. From design to operation: improving energy efficiency through the Prime-G+ lifecycle Energy efficiency improvements in refin- ing are best delivered through a struc- tured, methodical approach, combining proven engineering practices with technol- ogy choices that minimise intrinsic energy demand. Axens’ portfolio is designed to support operators at every stage of an asset’s lifecycle: from early paper design to end-of-life decisions. • Design : At the design stage, selecting a process scheme aligned with the refin- ery’s objectives is essential to build a sound foundation for energy efficiency. FCC gas- oline post-treatment is no exception: the scheme determines how deep desulphuri- sation is targeted, how much of the stream is exposed to hydrogenation, and how sep- aration duties are distributed. Prime G+ has demonstrated strong commercial success in part because of its high design flexibil- ity, enabling configurations tailored to feed quality and product targets, while aiming for minimal intrinsic energy demand and capital cost. • Catalyst : Once the unit skeleton is defined, catalyst choice becomes one of the most powerful levers for both performance and future improvement potential. Catalyst selectivity influences not only octane reten- tion, but also how hard the separation sec- tion must work and therefore how much energy the unit ultimately consumes.
olefins to treatment. This unlocks sub- stantial energy savings by relaxing splitter operation while preserving product quality targets. In some cases, 30% energy sav- ings can be achieved by adopting the latest generation of Prime-G+ catalysts. • Across the gasoline pool: selectivity avoids high-energy octane replacement. When FCC gasoline post-treatment pre- serves octane, the refinery can incorpo- rate more of the FCC-generated octane into the final pool. This reduces the need for octane ‘make-up’ from pathways that are often energy-intensive and costly, such as reforming and etherification, whether pro- duced on site or imported. In effect, selec- tivity improves the return on the energy already invested in upstream FCC conver- sion. It avoids spending additional energy to rebuild octane that was unnecessarily destroyed downstream. key takeAways Supplying cleaner fuels is a central com- ponent of the energy transition, and refin- ers play a critical role in delivering them at scale. Axens supports this effort as a long- term partner, providing technologies, cat- alysts, services, and operational support across the asset lifecycle. In many business cases, selectivity drives economics. The value gained from octane retention and util- ities savings far outweighs catalyst cost, making catalyst selectivity a powerful profit booster and energy savings tool. In South America, where Prime G+ and ethanol incorporation in gasoline are already widely implemented, energy efficiency upgrades are the next step to unlock addi- tional value from existing assets. Catalyst upgrades and operation optimisation are affordable, quick wins for refiners to deliver transportation fuels with a reduced carbon footprint and greater economic value. Through continuous innovation, Axens helps operators meet environmental objec- tives without compromising competitive- ness, turning sulphur compliance into a durable economic advantage and support- ing the long-term sustainability of clean fuel supply. DID YOU know? In some cases, 30% energy savings can be achieved by adopting the latest generation of Prime-G+ catalysts
• Energy engineering : Heat exchanger network optimisation, equipment selec- tion, and targeted innovations can fur- ther improve energy recovery and reuse, increasing the value extracted from every unit of energy spent. Employing high- efficiency heat exchangers around the hydrodesulphurisation (HDS) reactor plays a crucial role in reducing energy demand while improving HDS operation conditions towards more selectivity. • Operation optimisation : Delivered through Axens services, operational guid- ance, and digital tracking/optimisation tools, they help sustain ideal operation over time by preventing drift, inefficiencies, and energy-intensive production over quality. When consistently applied, thorough opti- misation creates a 20% reduction in H 2 and fuel gas consumption opportunity. • Ultimately, decarbonisation : Depending on site strategy, electrification and refin- ery-scale CO₂ capture solutions may com- plement efficiency measures. The key is sequencing: reduce energy demand first, then decarbonise the remaining energy footprint. For high‑CO₂‑impact equip- ment such as fired heaters, electrification reduces direct emissions, taking advan- tage of abundant and cost-free renewable power. Focus on catalytic solutions: selectivity as the hidden heavyweight of energy efficiency While the process scheme is a major con- tributor to Prime G+ performance, the cat- alyst remains at the core of the unit. It is where desulphurisation is achieved and where selectivity is ultimately determined. Prime G+ combines schematic intelligence with catalytic performance. Upstream of the splitter, the selective hydrogenation unit (SHU) reactor promotes a sulphur shift
that helps relocate sulphur species towards the heavier fraction. This enables smarter separation and limits unnecessary expo- sure of valuable light olefins to the HDS section. Downstream, the intrinsic selec- tivity of the HDS catalyst is critical to min- imise olefin saturation while achieving the required sulphur specification. Selectivity is widely recognised as a key economic driver because it protects octane and therefore gasoline pool value. However, it is also a powerful, often overlooked, energy vector in two distinct ways: • Inside the Prime G+ unit: catalyst selec- tivity can reduce splitter energy demand . The splitter is traditionally operated to max- imise olefin recovery in the overhead while still meeting sulphur targets in the light gasoline. This operating philosophy pro- tects octane by keeping olefins away from the HDS section treating heavier gasoline. However, it can also impose significant sep- aration duty, making the splitter a major contributor to unit energy demand. A more selective HDS catalyst changes the optimisation space. With higher selec- tivity, the unit can maintain the same global octane retention while tolerating a differ- ent split strategy, exposing slightly more
Contact: Arnaud.cotte@axensgroup.com jean-louis.beeckmans@axensgroup.com
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LARTC 2026
Data-driven fired heater performance recovery
Ella Boyden Integrated Global Services
Rising fuel costs, decarbonisation targets, and pressure to maximise asset utilisa- tion are driving refinery and petrochemical operators to examine every opportunity to improve fired heater efficiency. While opti- misation efforts often focus on burners, combustion control, and process tuning, a significant recurring source of energy loss is fouling in the convection section. Deposits accumulate on finned and bare tubes, reducing heat transfer from the flue gas to the process. The heater continues to operate, but less heat is recovered, stack temperatures increase, and additional fuel is required to maintain process duty. Since this deterioration occurs over extended operating periods, it is often accepted as normal rather than recognised as recover- able performance loss. For refinery and petrochemical opera- tors, these incremental losses can become significant. Internal thermal modelling dem- onstrates that a representative furnace experiencing a moderate 50°C increase in stack temperature can lose approximately 2-3% thermal efficiency, increasing fuel demand by around 4 MW. Across a five- furnace operation, this equates to almost $1.9 million in additional annual fuel costs before considering production impacts or increased emissions. Moving from maintenance to performance recovery Historically, convection section cleaning has been treated as a maintenance activ- ity, typically scheduled during turnarounds or undertaken when fouling becomes vis- ually apparent. However, this approach does not necessarily align intervention with the point at which energy losses jus- tify cleaning. Instead, an increasing number of oper- ators are adopting a performance-based strategy. By comparing measured oper- ating conditions with the original design parameters, thermal evaluations can quan- tify efficiency losses, estimate recoverable fuel savings, and identify the optimal point for intervention. Stack temperature, fuel consumption, and heat recovery become measurable indicators of economic per- formance rather than simple operating parameters. This approach shifts convection section cleaning from a reactive maintenance task to an evidence-based performance recov- ery programme. limitations of conventional cleaning Convection banks present unique mainte- nance challenges. Closely spaced finned tube arrangements create narrow flow passages where combustion ash and par- ticulate deposits accumulate over time. Conventional cleaning methods often struggle to reach deposits deep within tube banks, leaving residual fouling that continues to restrict heat transfer. Incomplete cleaning means that while visual improvements may be achieved, thermal performance is not always fully restored. Consequently, the true value
DID you know? Measured thermal performance, not visible fouling, should determine cleaning intervals
Performance recovery following convection section cleaning
Performance indicator Before cleaning
After cleaning -130°C (-234°F)
Stack temperature Thermal efficiency Fuel consumption
Elevated Baseline Baseline
+7.2%
-2.2 MW (7.5 MMBtu/h)
Figure 1 Remote robotic cleaning of convection tube banks enables full access to complex tube geometries while eliminating the need for confined-space entry
Annual operating cost
—
$900,000 saving
Cleaning coverage
—
100% accessible tubes Zero incidents
Safety performance
—
and reduced operating costs, improve- ments in fired heater performance can deliver significant financial returns without major capital investment. The key lesson is that fouling should no longer be assessed solely by visual inspection or fixed maintenance inter- vals. Instead, operators should monitor thermal performance indicators, quantify the value at risk, and schedule cleaning when measurable efficiency losses justify intervention. Conclusion As refining and petrochemical facili- ties continue to operate under increasing commercial and environmental pressure, improving fired heater efficiency repre- sents one of the most accessible opportu- nities to reduce energy consumption and operating costs. The remotely operated vehicle (ROV) cleaning case study demonstrates that combining thermal performance evalua- tion with high-coverage robotic cleaning can recover substantial efficiency losses, delivering measurable reductions in stack temperature, fuel consumption, and oper- ating costs while improving maintenance safety. Ultimately, convection section clean- ing should be viewed not simply as a maintenance activity but as a repeatable performance-recovery strategy. By basing intervention on measured thermal perfor- mance rather than elapsed operating time, refinery operators can make evidence- based decisions that maximise energy recovery, reduce emissions, and improve long-term asset profitability. Table 1 Measured steam cracker perfor- mance following robotic convection section cleaning
Figure 2 Convection section finned tubes before and after robotic cleaning. Removal of fouling restored heat-transfer surfaces and improved convective duty
economic justification for cleaning before work commenced. A remotely operated high-pressure water-cleaning system was deployed to clean four convection tube coils, each approximately 10 metres long. Cleaning was performed from multiple access points, enabling complete coverage of all accessible tubes and eliminating the need for confined-space entry. High-definition remote monitoring enabled the verifica- tion of cleaning progress throughout the operation. Beyond the direct energy savings, restoring convection section heat recov- ery improved radiant inlet temperatures, reduced radiant heat flux requirements, and created conditions expected to sup- port improved operating stability and longer run lengths between maintenance interventions. Wider implications for refinery operators Although this project was completed at a Brazilian ethylene facility, the engineering principles apply equally to refinery-fired heaters. Whether processing crude oil, vacuum gas oil, reformer feed, or petrochemical feedstocks, fired heaters rely on efficient recovery of waste heat within the con- vection section. Any deterioration in this heat recovery increases firing duty, raises stack losses, and reduces overall thermal efficiency. For operators pursuing lower emissions
of recovered heat transfer may remain unrealised. Robotic cleaning systems have been developed to overcome these access limi- tations. Remotely operated equipment can navigate complex tube geometries, clean from multiple access points, and elimi- nate the need for personnel to enter con- fined spaces during cleaning operations. Continuous visual monitoring also provides greater confidence that cleaning coverage has been achieved across all accessible surfaces. Steam Cracker case study demonstrates measurable performance recovery The benefits of this approach were demon- strated during a fired heater performance recovery project at a large olefin produc- tion facility in Brazil. Routine inspection identified significant fouling throughout the convection section, including deposits embedded between finned tubes, scale covering bare tubes, and increased accumulation in lower tube banks where particulate matter had set- tled. The fouling had progressively reduced heat transfer, increased fuel demand, and raised stack temperatures beyond normal operating expectations. Prior to the intervention, a thermal eval- uation predicted that restoring the cleanli- ness of the convection section would yield measurable improvements in thermal effi- ciency and fuel consumption. These pre- dictions established a clear technical and
Contact: ella.boyden@integratedglobal.com
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