Transcript Slide 1

IN THE NAME OF GOD
Mehdi Rashidzadeh
First International Catalyst Conference Tehran-IRAN 9 June 2014
1
Outline:
Drivers of Catalysis for Social development
Market and uses of catalyst
The long journey of an idea
Catalyst Importance for Iran
Examples of success Driven by R&D
Concluding Remarks
2
RIPI OVERVIEW
 Research Institute of Petroleum Industry:
 Founded in 1959
 Affiliated to National Iranian Oil Company (NIOC)
 Over 700 permanent employees (about 2000 including service contract staff)
 Nation's Largest research institute
3
Catalyst Preparation
Catalytic Reaction
Engineering
Characterization and
Evaluation of
Catalysts
Development of
carbon and
Nanotechnology
4
 More than 20% of GDP from products made using catalysts
 > 90% of petro refining and petrochemicals processes use
catalysts
 > 95% of pollution control technologies
 Catalysts has a strategic importance for the country economy
and …
5
Catalysis has a tremendous impact on the human activities as concerns economic
development, environment preservation and, more broadly, societal progress.
>90% of all molecules of transportation fuels
>80% of all chemical products
Are manufactured with catalysis
The development and scale-up of processes are, by definition, application oriented.
Industrial catalysis targeted to make in better processes resulting in :
Energy
efficiency
Economic
efficiency
Development of
Chemical Processes
Feedstock
efficiency
Environmental
efficiency
6
Catalytic processes require of a very particular industry for catalyst manufacture.
About 100 companies worldwide, <20 are the major ones, produce catalysts on their
own technologies or as toll manufacturers.
> $ 21000 million in 2011 catalysts sales
> $ 7,500 billion yearly induced market of manufactured goods.
Oil Refining (29 %)
Development of
Chemical
Processes
Chemical Processing (32%)
Including polymers & fine chemicals
Environmental Impact Control (39 %)
Catalyst sales per market sector
7
Over 80 million barrel of crude Oil are processed daily worldwide in >700
refineries.
The fundamental drivers determining the refinery mission are :
o
o
o
Ensure the energetic security,
Reduce the environmental impact:
Ensure Operation economics creating value for shareholders.
A refinery is an integrated sequence of technologies able to
Separate various hydrocarbon fractions,
o transform them in molecules suitable for the final use, and remove unwanted
impurities.
“ Any Part “ of crude oil must be utilized with environmentally friendly technologies.
o
Reaction technologies for petroleum refining consist almost entirely of catalytic
processes designed to modify the components of the fractions in four ways :
Breaking big molecules in smaller ones (cracking)
• Combining small molecules in larger ones (condensations)
• Rearranging “Part” of molecules for getting appropriate “structures”
(isomerization)
• Breaking carbon-heteroatom bonds (S, N, O, Me)
•
8
2%
11%
16%
32%
8%
39%
16%
18%
29%
29%
Fcc
Environmenta
l
Refining
Hydrotreating
Other
Hydrocracking
Polymers
Chemical
Alkylation
Reforming
9
7%
10%
20%
39%
17%
28%
6%
Europe
73%
Detergent Builders
Japan
Other Asia
North America
Catalysts
Adsorbents/Desicants
Rest of the World
10
- Qualified staff, experienced in different fields of sciences,
Engineering and Technology.
- High –tech equipments for physico- chemical characterization
and testing the catalytic performance.
- Pilot facilities for catalysts production and testing (Scaling-up)
- Innovative activity (Patent and legal services) and good
commercial partners.
11
An innovative process begins with an idea that is generated in the somebody’s mind.
Individual Creativity is the engine of ideas generation.
Creativity:
Seeing What everyone else has seen
And
Thinking what no one else has thought
(Albert Szent-Gyorgi)
Innovativeness implies an application of discoveries.
It is always true that “necessity is mother of invention”
12
Human progress has been always based on creativity and innovativeness that reflects the dualsim
Science-Technology, two different but strongly connected cultural Worlds.
Scale-Up is the conjunction between creativity and innovativeness.
Scale up transform the initial idea into innovation, through a long (and dangerous) journey.
And there are only few ideas that will cover the entire way !
Definition
Check
Even in a continuum, the R&D activities, can be
grouped into two basic stages:
• the “explorative and definition phase”, already
oriented, but still looking for a general definition
of the process, and
• the “intensive and development phase”, strictly finalized to
achievement of The complete technology know-how.
Optimization
Risk analysis
Commercialization
Front end design
Engineering
Construction
Start-up
Realization
13
As a consequence R&D projects undergo very considerable “attrition”, and the majority of
explorative projects are ended.
About 1 to 3% of ideas for a new process at the early research stage reaches commercialization.
Project at the development stage have a probability of about 10 to 25%, and at the pilot plant stage
of 40 to 60%.
The success rate for marginal modifications of existing technologies will be higher than that of
completely new processes.
Projects
innovation
15
16
University
Fundamental and basic research
Applied research
Product Development
Industry
More “R” than “D” in Developing Countries
17
R&D and its link
with businesses
1. R&D for existing businesses.
This will ensure the business is
able to exploit all opportunities
available to it
2. Drive new businesses.
Business
opportunities
will continually arise. R&D
will ensure that these can
be exploited
3. Exploratory research.
This helps to develop
understanding
of
technology that the
business is using or may
use
18
€
Commercialization
investment
Sales
R&D
investment
Cash flow
Science
base
Generic
Proprietary
technologies technologies
Time
Production
scale-up
Market
penetration
19
Catalysis and catalytic processes development involve skills coming from many complementary, independent
disciplines.
Industry-Academia collaborations enlarge the cultural basis of the projects, and educate industrial researchers to
apply new scientific concepts in their “real-world” and academic researchers to introduce “real problems” in their
world.
Catalysis needs integration and “bridging the gaps”:
 between catalyst preparation and performances,
 between model catalyst and working catalyst,
 between laboratory and industrial conditions,
 between reactor engineering and catalyst formulation,
 between electronic structure calculations at molecular level and experimental results, and not be forgotten,
between business and science
20
 Geopolitical Context
-Iran has huge oil and gas reserves
-During the coming decades oil will still be main source of energy.
- Some political issues (sanctions)
 Development in refining and petrochemicals
- There are 9 oil refineries throughout the country
-7 new refinery are under construction (they would be operational up to
2025)
- increasing the capacity of old refineries
- investment on new petrochemical complexes.
 high consumption (by considering the developing plants in refining and
petrochemical industry it would be more than 5000 ton/ year).
21
50
45
40
35
32
30
25
21
20
15
10
9
5
5
3
3
3
2
2
2
2
2
2
1
1
1
1
1
0.4
0.4
0.3
0.03
0
22
Developed Know-how
item
Available to be handed over
Gamma alumina as a catalyst support for naphtha reforming
1
catalysts
Handed over to industries
Naphtha reforming catalyst
2
Catalyst for demercaptanization of distillate and condensate
Molecular sieve zeolite 3A
3
One-stepped preparation of Isobutene dehydrogenation catalyst
Low temperature water gas shift catalyst
4
Steam reforming catalyst
ZnO for sulphur adsorption
5
Gasoil hydrodesulphurization catalyst
Naphtha hydrodesulphurization catalyst
6
Shaped different types of molecular sieve zeolite A
7
Precious metal recovery of spent catalysts
Gamma alumina as a catalyst support for
naphtha HDS catalysts
Aromatization catalyst (Pt-Sn/Al2O3)
Production technology of carbon nanotubes (single-walled, double8
walled and multi-walled)
Production of nanostructured metal oxides
9
Hydro-cracking process Simulator
10
11
Catalytic reforming process Simulator
23
 Naphtha Hydrotreating catalyst
 Naphtha Reforming catalyst
 Zeolites: 3A & 4A
24
Physical and chemical Specification of the Co-Mo/Al2O3 catalyst
Bulk Density
(g/mL)
Mean Pore
Diameter (nm)
Pore Volume
(mL/g)
Surface Area
(m2/g)
CoO
(wt%)
MoO3
(wt%)
Min.0.6
8-11
Min. 0.6
Min. 190
2-5
12-15
25
.
26
.
 Feed: Naphtha with 1200 ppm S (Total Sulfur)
 H2/Oil
 Pressure
 LHSV
175 Nlit/lit
15 bar
4.2 hr-1
Temperature ,°C
Total Sulfur in Product,
ppm
(Commercial catalyst)
Total Sulfur in Product,
ppm
(RIPI catalyst(
250
6
4
270
1
1
290
<1
<1
310
<0.5
<0.5
330
<0.5
<0.5
27
•Catalytic reforming of naphtha constitute a very important
source of products having high octane numbers which are
key components in the production of gasoline.
• Catalytic
reforming
is
the
process
of
transforming
hydrocarbons with low octane numbers to aromatics and
iso-paraffins which have high octane numbers.
28
bulk density
(g/ml)
Mean pore
diameter
(Ao)
Pore
volume
(cm3/g)
Surface
area
0.72-0.74
100-105
0.50-0.55
190-220
(m2/g)
Cl
Re
Pt
(wt%)
(wt%)
(wt%)
0.9-1.1
0.4-0.45
0.20-0.25
29
.
95
100
Syntesized Catalyst
Commertial Catalyst
70
100
80
75
85
80
60
70
86
40
20
0
RON of Product
(after 40h)
RON of Product
(after 150h)
C5+ wt % in Product
(after 40h)
C5+ wt % in Product
(after 150h)
Reaction condition , T:515 °C P:10bar LHSV:2h-1 H2/oil:5Nli/li
30
Synthesized catalyst in nano scale
Commercial catalyst
Synthesized catalyst by conventional method
31
Applications:
 Catalysis
 Gas separation
 Ion exchange
 Detergents
32
Zeolite 4A
powder
Salt Solution
Oven
Ion Exchanger
Crusher
Filter
Binder
Additives
Distilled Water
Blender
Kneader
Oven
Extruder
Screening
Furnace
Product
All ingredients and equipments used are from national sources
33
Specification for Zeolite 4A Powder
Na2O
Al2O3
SiO2
H2O
Blue Density (kgm-3)
Mean crystal size (𝝁 m)
pH (5% in water)
Calcium binding capacity
17 wt%
28 wt%
33 wt%
22 wt%
500-550
2.5
10.5
173.6 mg CaO/g Zeolite
Physical Properties of 3A Molecular sieve
Shape
Size
Bulk density, kgm-3
Crush strength, Mpa
Water adsorption, %
(at 60% relative humidity)
Extrudate
3-4 mm length
760
1.0
15.25
34
Novelty…
35
Catalyst preparation (Lab & Pilot scale)
Catalyst evaluation
Industrial production
36
37
38
39
 catalysts performance are evaluated at bench and pilot scale. Major
units in this section are for the following processes:
 Steam Reforming
 Hydrocracking
 Hydrotreating(Naphtha, Kerosene, Gasoil)
 Low temperature shift conversion (LTSC)
 High temperature shift conversion (HTSC)
 S-Absorptions
 Catalytic reforming
 Isomerization
40
*Used by Permission PP&C.
41
NEW TECHNOLOGIES
RIPI
P ROJECTS
Research
Lab Test
Bench
Scale
Commercial
Scale
Patenting
Pilot
Plant
Industrial
Plant
Nano Lubricants
ULW Cement
NANO fuel additives
Nanomaterials for
oil decontamination
Polymer
Nanocomposites
Nanocatalysts
Upgrading oil products
quality by Nanomaterials
Nanocoatings
CNT mass production
42
 During the coming decades, oil will still be the main source of





energy and so it is necessary to develop the better catalysts for
catalytic processes.
Industrial catalyst producing is of strategic importance for any
developing country and without dubte it belongs to the category
of the so-called "high-tech" industries.
It should be emphasized that without intensive research and
development activities it is impossible to reach and maintain of
catalyst production.
Industry should play the leading role, which is especially
important. It has the provider of founding for R&D teams.
The companies which produce catalyst, have to support big
research teams and extensive multimillion R&D programs.
Catalyst developers must be support the industry and give them
suitable guarantees and technical services.
43
44