basf multi stage reaction catalysts
DESCRIPTION
BASF Multi Stage Reaction CatalystsTRANSCRIPT
-
Page 1
Multi-Stage Reaction Catalysts:
A Breakthrough Innovation in FCC Technology
J. B. McLean, B. W. Hoffer, G. M. Smith, D. M. Stockwell, and A. S. Shackleford
BASF Corporation, Catalysts Division
Introduction
BASFs Multi-Stage Reaction Catalyst (MSRC) platform is a breakthrough in FCC manufacturing.
The innovative manufacturing development takes advantage of staged reactions with different
catalytic attributes in much the same way that staged hydrotreating catalyst loading permits
different reaction zones in a fixed-bed reactor vessel. The concept of staged reactions is not new
to the refining industry, but its application to a circulating system such as FCC is a true
advancement in catalyst technology.
The manufacturing platform can utilize any of the existing catalyst technologies including BASFs
Distributed Matrix Structures (DMS)1,2 and Proximal Stable Matrix and Zeolite (Prox-SMZ)3,4 to
create the stages. The location of the various stages can be specifically engineered to achieve
maximum value for the customer. There are a myriad of possibilities for combining different
catalyst technologies in the inner and outer stages depending on the specific objectives such as
the processing of heavier feedstocks or to maximise specific product yields.
This novel manufacturing process is based on in-situ technology and involves several key
sequential manufacturing steps. One of the key success factors in the development of MSRC
technology is the binding process, unique to the in-situ manufacturing process, where Y zeolite
grows across the boundary between catalyst stages, acting as a binder and giving the catalyst
particle excellent attrition resistance properties.
The first product utilizing MSRC manufacturing is Fortress. Fortress is designed for resid feed
applications, where contaminant metals passivation is critical. MSRC manufacturing technology
was successfully scaled up and demonstrated in 2010 with Fortress, and two refinery trials were
initiated.
HALO the second catalyst offering from BASF under the Multi Stage Reaction Catalyst
manufacturing platform will be ready for commercial trials in 3 Q 2011. HALO is engineered to
-
Page 2
provide attrition resistance comparable to Petromax with equivalent yields, coke and bottoms
selectivity to NaphthaMax III. As with Fortress, a two stage system is used but in this case it
delivers an outer stage with highly active zeolite. The staged approach allows for a reduction on
the level of Y zeolite in the particle as well as a reduction in the diffusion path length. The inner
stage is composed of activity modifying material which also serves as an anchor for the outer
stage. Due to the reduced level of zeolite in the catalyst particle, there is an additional benefit to
HALO in the form of a reduction of RE level with no performance deficit.
MSRC Concept
The approach of the new BASF Multi-Stage Reaction Catalyst (MSRC) platform is to combine two
or more existing FCC catalyst functionalities within a single catalyst particle. The location of the
various stages can be specifically engineered to achieve maximum value for the customer. This
can be related to processing of heavier feed stocks, or to maximize specific product yields in the
FCC unit. The MSRC platform can include existing catalyst technologies like DMS (for gasoline
maximization) or Prox-SMZ (diesel maximization), but is based on a novel and unique
manufacturing concept.
The first product from this new platform, Fortress, is designed for resid feed applications, where
contaminant feed metal passivation is crucial. In particular, traces of nickel in the resid feed have
a detrimental effect on the catalyst performance. In state of the art resid FCC catalysts like Flex-
Tec, a specialty alumina is integrated in the catalyst formulation to trap the nickel and form
nickel aluminate which is less deleterious for dehydrogenation reactions in the FCC riser. By
examining spent FCC catalysts from refineries with electron microscopy, it was generally
observed that while vanadium is distributed homogenously through the particles; nickel mainly
deposits and accumulates on the outer surface of the catalyst, as depicted in Figure 1. It would
thus be advantageous to concentrate the nickel trapping alumina at the outer layer of the catalyst
to make it more effective. With current catalyst technology the specialty alumina is uniformly
distributed through the catalyst microsphere. This makes a large portion of it, located in the
interior of the particle, unavailable to react with the nickel and is essence wasted.
BASF has addressed this situation using the MSRC approach. The inner stage of the catalyst has
the DMS structure to allow enhanced diffusion of heavy molecules and selective pre-cracking on
the exposed zeolite surface, maximizing gasoline yields (Ref. 1). The outer-stage is also based
on DMS technology, but is enriched with specialty alumina to trap the nickel directly where it
enters and deposits on the catalyst as depicted in Figure 2. The technology is analogous to that
-
Page 3
employed with Flex-Tec (Ref. 2) and Stamina (Ref. 4), but with the improved spatial distribution of
the trapping alumina offers more efficient material utilization and better performance potential.
The manufacturing process for this two-stage reaction catalyst is based on BASFs unique DMS
manufacturing technology and involves multiple consecutive steps (Fig. 3). First a precursor
microsphere based on proven DMS technology with a reduced particle size is formed. This
microsphere is then added to a second slurry, which has a Flex-Tec like formulation including
elevated concentrations of the nickel passivating specialty alumina, and spray-dried again to yield
a two-stage microsphere with the required final FCC particle size.
The FCC catalyst is then manufactured by growing zeolite from the kaolin nutrients in the multi-
stage microsphere. The zeolite grows in both stages and across the interface and will act as a
binder to hold the stages together, preventing selective attrition of the outer stage. Zeolite growth
and catalyst activity are in line with current DMS platform products, as are all physical properties.
These novel MSRC and Ni passivation enhancement concepts result in cost-effective resid FCC
performance that is a breakthrough innovation and offers rich potential for future MSRC
applications.
Development of Fortress
The basis for the development of the Fortress catalyst was the observation that Ni accumulates
mainly in the outer 5-10 microns of the equilibrium FCC catalyst (Ref. 5). This is depicted in
Figure 1. Geometric calculations show that the weight ratios of the two stages for a ~8 micron
outer stage thickness and a normal FCC particle size distribution are about 1:1. The addition of a
solid inner-stage particle to the recipe makes the production of MSRC more complex than
existing FCC catalysts. Scanning electron microscopy of the early samples clearly demonstrates
the multi-stage configuration of the particles (Fig. 4). By modifying the microsphere formulation,
the density of inner and outer stage components were optimized in order to allow maximum
diffusion rates, without impacting the staged configuration. After successful demonstration of
manufacturing MSRC catalysts on pilot scale and encouraging testing data, the project was
quickly transferred to commercial manufacturing scale. The plant production trials required the
capabilities of multiple manufacturing plants to make first the inner stage microspheres, followed
by the construction of the outer stage material, and finally zeolite crystallization and finishing to
make the catalyst (see Fig. 2).
-
Page 4
The particle size distribution of the resulting MSRC microspheres is shown in Fig. 6. The graph
shows that the inner stage particle has an average particle size (d50) of 64 m and the final
particle (inner + outer stage) of 80 m, resulting in an average outer stage thickness of 8 m. The
thickness is fairly constant throughout the particle size distribution. This is important since the
expected Ni penetration depth would be fairly constant across the entire particle size range, so
that both larger and smaller particle sizes should have comparable outer stage thickness.
The attrition resistance of the commercially manufactured catalyst was measured with two
standard attrition testing techniques: Roller and Airjet (Table I). The table shows that attrition
properties are very similar to Flex-Tex, indicating that the two stages are very well connected and
form a mechanically stable particle. Since the zeolite grows between and chemically bonds to the
DMS matrix support materials in both stages, attrition resistance and other physical properties
such as density are not any different than existing DMS products such as Flex-Tec. This was
also validated in the commercial performance, which is described later in this paper.
Table I. Attrition properties
Flex-Tec Fortress
Roller (wt% loss/h) 18 16
Airjet Rate* (wt% loss/h) 2.7 2.9 * Losses in first hour of operation are disregarded
The product from the first manufacturing campaign was evaluated in the lab using BASFs ACE
bench scale testing unit. ACE testing was done with a commercial resid feed at 960F and
variable cat/oil ratios to generate yield response curves. The performance of Fortress was
compared to the Flex-Tec catalyst that was being supplied to the target trial refinery FCC unit.
Prior to ACE testing the samples were deactivated and metallated using BASFs Cyclic
Metallation and Deactivation Unit (CMDU) with intermediate steaming to target approximately
2800 ppm Ni and 1100 ppm V, as well as commercially representative equilibrium catalyst activity.
Table II shows the properties of the pseudo-equilibrium catalysts. As stated earlier, the chemical
and physical properties of Fortress are very similar to Flex-Tec; the difference is the distribution of
alumina: concentrated in the outer-stage (Fortress) versus uniform (Flex-Tec).
It must to be noted that the proper laboratory preparation of a pseudo-equilibrium catalyst for a
resid cracking performance evaluation is not trivial. This is because conventional (Mitchell) pore
volume impregnation methods result in Ni distributed uniformly throughout the catalyst microsphere, thus penetrating much further into the microsphere than observed on an FCCUs E-
-
Page 5
cat. Because H2 production from impregnated metals is a linear process, Fortress and Flex-Tec
will appear to have the same Ni tolerance by pore volume impregnation. Resid FCC units on the
other hand will result in Ni deposition mostly on the alumina-enriched outer stage however, so the
correct answer will be for MSRCs to outperform catalyst technologies employing uniformly
dispersed active ingredients. This correct answer cannot be obtained by pore volume
impregnation.
Table II. Properties of catalysts for ACE testing
Flex-Tec Fortress
Fresh
TSA (m2/g) 300 301
MSA (m2/g) 72 69
REO (wt %) 3.1 3.7
APS (m) 76 76
0-40 m (wt %) 11 10
0-80 m (wt %) 54 55
Deactivated (CMDU)
Ni (ppm) 2797 2718
V (ppm) 1133 1050
Steamed TSA (m2/g) 115 123
Steamed MSA (m2/g) 36 38
ZSA/MSA 2.2 2.2
The ACE results are listed in Table III. Fortress catalyst hydrogen and coke yields were reduced
with about 15% at similar metal content as Flex-Tec, with a corresponding increase in gasoline
yield. Clean testing in absence of metals showed no differences in coke and bottoms yields,
demonstrating that no diffusion limitations occur in lab testing and that the effect observed in
metals testing is a passivation effect. Since H2 production is a direct measure of metals
dehydrogenation activity, it is clear that Fortress is achieving improved passivation. This is in line
with the laboratory prototypes as shown in Figure 5.
-
Page 6
Table III. Product yields (wt %) at 70% conversion
Flex-Tec Fortress
Hydrogen 0.53 0.44
Total C4- 15.9 15.5
Gasoline 49.4 50.4
LCO 20.1 20.1
HCO 9.9 9.9
Coke 4.7 4.1
-
Page 7
Fig. 2. Simplistic representation of alumina distribution in current resid catalyst
Flex-Tec (left) versus novel MSRC resid catalyst technology (right).
clay slurry
H2Odryer
calciner
Step 1: Inner stage microsphere
Alumina free Inner stage MS(~65 m)
clay slurry
H2Odryer
calciner
Step 1: Inner stage microsphere
Alumina free Inner stage MS(~65 m)
clay slurry+ alumina+ Inner stage MS
H2Odryer
calciner
Step 2: Outer stage microsphere
Two-Stage MS(~80 m)
clay slurry+ alumina+ Inner stage MS
H2Odryer
calciner
Step 2: Outer stage microsphere
Two-Stage MS(~80 m)
Step 3: Zeolite crystallization and after-treatment
MicrosphereCausticSilicate
BaseExchange
Rare-earthExchange Calciner
Multi-Stage ReactionCatalystNa-Y
Step 3: Zeolite crystallization and after-treatment
MicrosphereCausticSilicate
BaseExchange
Rare-earthExchange Calciner
Multi-Stage ReactionCatalystNa-Y
Fig. 3. Manufacturing sequence of MSRC technology
Alumina
Fortress (Resid MSRC) Flex-Tec
-
Page 8
Fig. 4. SEM pictures of early MSRC lab samples show multi-stage concept
0.20
0.25
0.30
0.35
0.40
0.45
0.50
65.0 70.0 75.0 80.0
Conversion, Wt%
Wt%
Hyd
roge
n FlexFlex--TecTec
FortressFortress
Fig. 5. Hydrogen yield in ACE testing of lab sample of Fortress compared to Flex-
Tec. The samples were deactivated with CMDU to 3000 ppm Ni and 1000 ppm V
Core shell catalyst with lower density cores
-
Page 9
0
20
40
60
80
100
0 30 60 90 120 150
Inner stage
+ Outer stage
% finer than
particle size (micron)
Fig. 6. Particle size distribution of inner stage and final plant produced
microspheres
Commercial Performance of Fortress
Fortress entered into the first of two commercial trials in the second half of 2010. The trial that is
furthest along is a short contact time resid unit located in the United States. The unit operates in
deep partial burn and low reactor severity, with primary constraints of wet gas compressor and air
blower limited. The refiners economic objects are to maximize residue rates while minimizing
bottoms yields. With the excellent metals tolerance of Fortress, the expected reduction in
hydrogen yield can be reduced to alleviate the wet gas compressor limit, and the improvement in
coke selectivity can allow more operating flexibility within these constraints.
The unit was using Flex-Tec with together with purchased equilibrium catalyst (ECat) for metals
flushing. Flex-Tec had replaced a competitive catalyst in early 2010 based on the results of a
catalyst evaluation. For the cleanest comparison, the purchased ECat was removed prior to the
start of the trial. As such there are three different periods of operation compared: Flex-Tec with
Ecat, Flex-Tec without Ecat, and Fortress without Ecat.
The trial was supported by analysis of the refinerys ECat and fines data. The refinery sent twice
weekly ECat samples and weekly fines samples. Samples enter the BASFs Refinery Returns
system and are systematically analyzed for chemical properties, physical properties, activity and
-
Page 10
selectivities. The activity and selectivities are measured on an Advance Cracking Evaluation
(ACE) unit. This is a standardized testing method using a fixed fluid bed, which simulates SCT
(short contact time) riser performance. It runs all the ECats under the same conditions (feed,
temperature, and cat:oil ratio) providing a good basis for comparison. Below are the typical ECat
values for before and after the purchased ECat was removed.
With the removal of purchased ECat, the metals increased due to lower catalyst addition rates.
Nickel alone increased from ~7,500 ppm to ~9,500 ppm. Despite the increase in metals, the
hydrogen make off the ACE unit did not increase as showing in Figure 7. Equivalent nickel in
Figure 7, calculated by Ni + V/4 + Fe/10 + 5 Cu 4/3 Sb, represents the equivalent
dehydrogenation activity of the metals on the ECat and the antimony passivation effect.
Transitioning from Flex-Tec without purchased ECat to Fortress without purchased ECat, the
hydrogen selectivity off the ACE improved by 12%. The cross plot of the data in Figure 8 shows
how the average hydrogen yield decreased from 0.41 wt% to 0.36 wt% with Fortress,
demonstrating the improved metals passivation.
FACT 71 wt%Nickel 7400 ppmVanadium 2600 ppmDelta Iron 0.23 wt%Antimony 2000 ppmLead 100 ppmCarbon on Catalyst 0.2-0.5 wt%Equivalent Nickel 5600 ppm
With Purchased ECatFACT 71 wt%Nickel 8900 ppmVanadium 2700 ppmDelta Iron 0.30 wt%Antimony 2300 ppmLead 100 ppmCarbon on Catalyst 0.2-0.6 wt%Equivalent Nickel 6800 ppm
Without Puchased ECat
-
Page 11
0.2
0.3
0.4
0.5
0.6
0.7
-200 -150 -100 -50 0 50 100Day
AC
E H
2 Yi
eld
30003500400045005000550060006500700075008000
Equi
vale
nt N
icke
l (pp
m)
ACE H2 Yield ECat Equivalent Nickel
Fortress w ithout Ecat
Flex-Tec w ithout Ecat
Flex-Tec w ith Ecat
Figure 7: Figure ACE Cat lab data during the trial period, ACE hydrogen yield and
ECat equivalent nickel
0.20
0.25
0.30
0.35
0.40
0.45
0.50
0.55
5000 5500 6000 6500 7000 7500 8000Equivalent Nickel (ppm)
AC
E H
2 Yi
eld
(wt%
)
Flex-Tec w ith Ecat Flex-Tec w ithout Ecat Fortress w ithout Ecat
Figure 8 ECat lab data during the trial period, ACE hydrogen yield versus ECat
equivalent nickel
-
Page 12
The improved metals tolerance of Fortress can also be seen by the improvement in coke
selectivity. Figure 9 shows the ACE coke factor (coke yield adjusted for activity) as it
corresponds to the equivalent nickel. As with the ACE hydrogen yield, the removal of purchased
ECat did not increase the coke factor despite the increase in equivalent nickel of over 1000 ppm.
With Fortress, the coke factor has significantly decreased. Comparing the ACE coke yield from
the transition of Fortress to Flex-Tec (Figure 10), the coke yield decreased by 17%. This
dramatic decrease in coke of ~0.7 wt% for the same conversion is unexpected. A general rule of
thumb is a 7:1 ratio of hydrogen reduction to coke reduction. With a hydrogen yield reduction of
0.05 wt% this corresponds to an expected 0.35 wt% reduction in coke. A reduction in coke of
~0.7 wt% is twice what can be explained from the hydrogen reduction, and in a positive direction.
1.0
1.3
1.6
1.9
2.2
2.5
-200 -150 -100 -50 0 50 100Day
AC
E C
oke
Fact
or
3000
35004000
45005000
5500
60006500
70007500
8000
Equi
vale
nt N
icke
l (pp
m)
ACE Coke Factor Equivalent Nickel
Figure 9 ECat Lab Data during the trial period, ACE Coke factor and Equivalent
nickel
-
Page 13
2
2.5
3
3.5
4
4.5
5
5.5
6
66 68 70 72 74 76
ACE Conversion (wt%)
AC
E C
oke
Yiel
d (w
t%)
Flex-Tec w ith Ecat Flex-Tec w ithout Ecat Fortress w ithout Ecat
Figure 10 ECat Lab data during the trial period, ACE coke yield versus ACE
conversion
Since less mass is being converted into hydrogen and coke, the delta mass is showing up as 0.7
wt% more LPG + Gasoline Yield (Figure 11). A commercial unit can further realize addition
benefit from the improved coke selectivity by being able to lower the regenerator temperature
thus increasing cat:oil ratio or by lowering the CO2/CO ratio resulting in increased liquid yield.
As expected from the fresh catalyst properties, there were no changes observed in attrition or unit
losses from the transition from Flex-Tec to Fortress. The particle size distribution of the fines
from the ESP shows no change across the transition (Figure 12).
-
Page 14
61.061.562.062.563.063.564.064.565.065.566.0
67 68 69 70 71 72 73 74ACE Conversion (wt%)
AC
E LP
G +
Gas
olin
e (w
t%)
Flex-Tec w ithout Ecat Fortress w ithout Ecat
Figure 11 ECat Lab data during the trial period, LPG + Gasoline vs. Conversion
0
2
4
6
8
10
12
14
16
0.1 1 10 100 1000
Particle Size (microns)
Frac
tiona
l (%
)
Day 103 Day 68 Day 40 Day -3 Day -72
Figure 12 ESP Fines PSD shows no changes
-
Page 15
A post-audit study of the trial was completed on the ACE unit using the refiners feed and
mimicking the refiners operating conditions comparing the fully changed out Ecat samples of
Flex-Tec and Fortress. The ACE comparison shows a decrease in hydrogen of 15%, decreasing
from 0.65 wt% to 0.55 wt%. The coke yield decreased by 0.5 wt% for the same conversion. This
is in complete alignment with both expectations and the data already discussed from the routine
Ecat monitoring. Some of the results are shown in Figure 13.
-
Page 16
Figure 13: ACE Post-Audit testing using the refinery feed and mimicking the
refiners operating conditions
0.40
0.45
0.50
0.55
0.60
0.65
0.70
0.75
0.80
60 65 70 75 80
Conversion (wt%)
Hyd
roge
n (w
t%)
Flex-Tec Fortress
50
52
54
56
58
60
62
64
66
60 65 70 75 80
Conversion (wt%)
LPG
+ G
asol
ine
(wt%
) Flex-Tec Fortress
2.0
2.2
2.4
2.6
2.8
3.0
3.2
3.4
3.6
3.8
60 65 70 75 80
Conversion (wt%)
Dry
Gas
(wt%
)
Flex-Tec Fortress
6
8
10
12
14
16
18
60 65 70 75 80
Conversion (wt%)
Bot
tom
s (w
t%)
Flex-Tec Fortress
5
6
7
8
9
10
11
12
13
14
60 65 70 75 80
Conversion (wt%)
Cok
e (w
t%)
Flex-Tec Fortress
6
8
10
12
14
16
18
6 8 10 12 14
Coke (wt%)
Bot
tom
s (w
t%)
Flex-Tec Fortress
-
Page 17
There is a second trial of Fortress at another US refinery. The expected benefit of the improved
nickel passivation in this unit is expected to be slightly less than the prior unit because the nickel
is less at 3000 ppm. Like the previous refinery, this is a comparison to Flex-Tec and purchased
ECat was removed from the inventory. The typical ECat properties before and after the removal
of purchased ECat is shown below. Another feature of this unit is a very high level of
contaminant iron (~ 1 wt%). At this time the unit is operating well with Fortress but it is too early
to tell the results of the trial.
Conclusions
The MSRC manufacturing concept represents a breakthrough development in FCC catalyst
technology. Through this novel multi-stage approach to catalyst manufacturing, BASF is able to leverage
the success of its proven FCC catalyst technologies and enable the development of next generation catalysts
that address the challenges and objectives of refiners in today's rapidly evolving refining landscape. The
first product based on BASFs FCC catalyst concept MSRC, Fortress, has been developed and scaled up to
commercial production and is demonstrating improved performance in metals passivation in early refinery
trials.
BASF is currently undergoing manufacturing trials for the second product based on the MSRC
concept. HALO is engineered with an outer stage of highly stable zeolite resulting in a reduced diffusion
path length which improves selectivity, delivers high bottoms conversion with low coke, and high gasoline
and light olefin yields. The reduced diffusion path length achieved through the MSRC manufacturing
process enables HALO to deliver high performance, consistent with BASFs Distributed Matrix Structures
(DMS) based products, while exhibiting better attrition characteristics as a result of the high opacity.
BASF intends to expand the number of Fortress applications, commercially launch HALO, and introduce
other exciting new technologies based on the MSRC concept.
FACT 71 wt%Copper 70 ppmNickel 2700 ppmVanadium 2200 ppmDelta Iron 0.9 wt%Antimony 600 ppmLead 200 ppmEquivalent Nickel 3400 ppm
With Purchased ECatFACT 69 wt%Copper 70 ppmNickel 3500 ppmVanadium 3200 ppmDelta Iron 1.1 wt%Antimony 900 ppmLead 200 ppmEquivalent Nickel 4200 ppm
Without Puchased ECat
-
Page 18
References
1) NaphthaMax - Breakthrough FCC Catalyst Technology for Short Contact Time
Applications; J. B. McLean and D. M. Stockwell, NPRA AM-01-58
2) Distributed Matrix Structures a Technology Platform for Advanced FCC Catalytic
Solutions; J. B. McLean, W. A. Weber, and D. H. Harris, NPRA AM-03-38
3) The Role of FCC Catalyst Technology in Maximizing Diesel Production, J. B. McLean,
NPRA AM-09-34
4) Stamina - New FCC Catalyst for Maximum Distillate Yield Demonstrated in Big Wests
Salt Lake City Refinery; M. Kraus, N. Kiser, Q. Fu, J. Yang, O. Thornton, and J. Finch,
NPRA AM-10-171
5) Kugler, E.L., and Leta, D.P., Journal of Catalysis 109 (1988), 387.
Authors: Joseph B. McLean BASFGlobal Technology Manager [email protected] With our 35 years of experience, Joe has led the market introduction of BASFs Distributed Matrix Structures (DMS) and Proximal Stable Matrix and Zeolite (Prox-SMZ) platforms. He holds a BSChE from Princeton University, an MSChE from the University of California, and several patents. Alexis S. Shackleford BASFTechnical Support Engineer [email protected] Prior to her work at BASF, Alexis was a Process Engineer working with refinery process units. She holds a BSChE from Michigan State University with a minor in Biochemical Engineering. Alexis currently manages the best-in-class Technical Services program that BASF offers to its refinery clients. David M. Stockwell BASFSenior Research Associate [email protected] David has over 25 years experience with BASF (formerly Engelhard) developing products and solutions specifically for the FCC industry. David was the principal inventor for BASFs ground-breaking Distributed Matrix Structures (DMS) technology platform, which enabled the NaphthaMax product; and most recently the Multi-Stage Reaction Catalyst (MSRC) manufacturing platform. He holds a B.S. degree from the University of Rochester and a M.S., and Ph.D. from the University of Connecticut. David current holds 17 U.S. Patents. Bram W. Hoffer BASFSenior Research Engineer
-
Page 19
[email protected] Bram has led the Fortress R&D program from lab phase up to commercial trials in the FCC manufacturing plants. He has over 7 years of experience in industrial catalyst development and worked for BASF in Germany, Belgium and USA. Bram holds a PhD and MS in Chemical Engineering from Delft University of Technology, The Netherlands, and holds six US patents. Gary M. Smith BASFResearch Chemist [email protected] Gary is a Research Chemist with 30 years experience in FCC catalyst research and development. In addition to MSRC, he has worked on the development of a number of catalyst technologies, including MOA (Maximum Olefins Additive) and holds 4 patents.