A Mark Schmalfeld, Global Marketing Manager, Refining Catalyst, BASF Corporation, mark.schmalfeld@basf.com In today’s dynamic refining landscape, FCC-focused refin- ers must continually adapt their operations to meet evolving market demands and changing economics. Various strate- gies can be employed: encompassing process changes, catalyst adjustments, and operational modifications that enhance resilience and profitability. One critical aspect is feedstock flexibility. By diversifying the feedstock slate, refiners can optimise their operations and improve profitability. Incorporating a range of crude oils or lighter feedstocks enables refiners to respond effectively to fluctuations in crude prices and availability. This flexibility allows for the maximisation of higher-margin products by selecting feeds that align with current market demands and economics. Additionally, blending different feedstocks can mitigate risks associated with supply disruptions and price volatility. Optimising operating conditions is another essential strat- egy. Fine-tuning parameters such as temperature, pres- sure, and residence time can significantly impact the yield and quality of products produced in the FCC unit. By closely monitoring and adjusting these conditions, refiners can enhance the conversion of feedstock into desired products, whether gasoline, diesel, or petrochemical feedstocks. This optimisation not only improves efficiency but also aligns pro- duction with market trends, enabling refiners to capitalise on higher-demand products. The integration of the FCC unit with other refining units, such as hydrotreaters, reformers and even petrochemical facilities, can create synergies that enhance overall opera- tional efficiency. This integration enables better manage- ment of product slates and maximises yields by ensuring that intermediate products are processed efficiently. Coordinating operations among these units can lead to improved energy utilisation and reduced emissions, allowing refiners to quickly adapt to changing market conditions. Choosing the right FCC catalyst and FCC additives is criti- cal for maximising profitability in FCC operations. Different catalysts can be engineered to enhance specific product yields, such as increasing gasoline, diesel, propylene or butylene production based on current market demands. Continually evaluating and selecting catalysts that align with market trends can improve a refiner’s competitive edge. Furthermore, advanced catalyst technologies can help reduce operational issues and extend catalyst life, leading to lower overall costs. Implementing a flexible operational strategy allows refin- ers to quickly adapt to changing market conditions. Rapid adjustments to process parameters enable a timely response to fluctuations in product demand or feedstock availability. This agility improves profitability and enhances overall refin- ery resilience, positioning it to navigate market uncertainties effectively. Investing in training and development for refinery per- sonnel is crucial for adapting to changing market condi- tions. Equipping operators with the latest knowledge and skills enhances decision-making and operational efficiency. Continuous training programmes focusing on emerging
technologies and best practices ensure that staff can effec- tively respond to market fluctuations, improving the refin- ery’s adaptability and performance. A Jaime Brito, Executive Director, Refining & Oil Products, Chemical Market Analytics, jaime.brito@chemicalmarketa- nalytics.com The answer can be as diverse as the location for every refin- ery. US Gulf Coast (USGC) refiners have the competitive advantage of being close to exporting facilities that can reach out to markets like the Caribbean, Central or South America, all of them with such optionality for different octane, aromat- ics, emissions, and distillation specifications, making exports feasible. In that sense, if a USGC refiner, mainly supplying domestic markets, has lost competitiveness versus other peers amid lower gasoline demand patterns, it can always focus on maximising exports to Latin America. Any moment in the year is a trade opportunity, as when summer season wanes in the northern hemisphere, traders in the southern hemisphere are seeking cargoes for their summer season, and vice versa. Refiners in other US markets would need to focus on specific arbitrage opportunities among the Mid Continent and the East Coast or the Rockies, as well as opportunities on US West Coast markets. A Boheng Ma, Strategic Marketing Manager. W. R. Grace & Co., boheng.ma@grace.com, Disha Sharma, Strategic Marketing Manager, W. R. Grace & Co., disha.sharma@ grace.com FCC units are widely regarded as one of the most flexible and resilient processes in a refinery, able to easily adapt to shifting feed slates and yield targets between turnarounds and revamps. The continuous addition and turnover of catalyst and additive in an FCC unit allows refiners to utilise catalyst and additive technologies as a key lever to adapt to changing market conditions in the middle of a run. Operating condition adjustments and the application of digital tools are other ways that refiners can remain nimble and respond to dynamic market conditions. Catalyst formulation adjustments can enhance FCC unit performance in response to varying feedstock properties, unit constraints, or yield objectives. They can provide benefits such as improved metals tolerance, enhanced bottoms upgrading, or optimised coke selectivity, among others. Additionally, key FCC product yields such as gasoline, butylene, and propylene can be effectively tuned through the strategic use of ZSM-5 additives. By adjusting the type and dosage rate of ZSM-5 additives, refiners can dynamically shift the yield profile to align with market conditions and economic objectives. These catalyst and additive modifications can be seamlessly imple- mented mid-run, without requiring unit downtime. To illustrate this adaptability, a unit operating in high pro- pylene mode with Grace’s OlefinsUltra MZ ZSM-5 additive can reduce its usage to shift selectivities toward gasoline as gasoline margins strengthen. Alternatively, if octane valua- tion or butylene becomes more valuable, refiners can switch to an additive that delivers a higher C4=/C3= ratio, increasing butylene production from the unit. Another scenario is when economic signals favour the
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PTQ Q4 2025
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