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
350 300 250 200 150 100 50 450 400 500
FUSION
Traditional catalyst systems
0
10
100
1000
10000
Pore size (Å)
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
Catalyst addition wet TPD
Wet add rate, lb/BBL
+27%
+12%
+18%
+6%
+9%
Base
Base
-9%
-6%
-18%
-12%
1 - Competitor Catalyst 2 - FUSION
-27%
-18%
-36%
1/1/25
3/1/25
5/1/25
7/1/25
1/1/25
3/1/25
5/1/25
7/1/25
Date
Contact: Akash.Pahuja@grace.com Michael.Hawkins@grace.com
Figure 3 Catalyst addition rate
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