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
9
Powered by FlippingBook