Worldwide Catalyst Report: Refiners' hydroprocessing needs drive catalyst portfolio change
If necessity is the mother of invention, then looming reformulated motor fuel regulations in the form of low sulfur specifications create the necessity for the invention of, among other things, new and creative desulfurization technologies. This in turn compels catalyst suppliers to change their product portfolio to compliment emerging desulfurization engineering. Rising to the challenge, catalyst companies are releasing state-of-the-art hydroprocessing catalysts.
Hydrotreating units historically processed fairly sweet crudes. Hydrorefining, on the other hand, referred to more severe operating conditions used to remove heavy contaminants.
Today, more stringent regulations and a shift toward increasingly sour crude processing eliminate the need for such distinction because hydrotreating units tolerate higher temperature and pressure.
Therefore, this year's OGJ International Refining Catalyst Report no longer includes a hydrorefining category. Consequently, redundant catalyst listings have been removed. This reduced list shows 781 catalyst formulations when compared with the OGJ 1999 survey that tallied 825. Also removed is the "availability" column, and purchasers' inquires for pricing, availability, and licensing requirements should be directed to catalyst suppliers.
The following article describes some of the more important developments since the last catalyst report.
Mergers, acquisitions
During 2000, M&A activity further changed product portfolios.
In February 2000, W. R. Grace & Co.'s Davison Catalyst acquired Crosfield Catalyst Co. LP business unit. This was the only company removed from the survey and as a result reduced the number of catalyst suppliers to 26 from the 27 listed in the last report. The resulting entity introduced a slate of clean fuels technology catalysts, including SuRCA, D-PriSM, and RFG.
The hydroprocessing catalyst business (excluding hydrocracking catalysts) of Grace Davison combined with Chevron USA's hydroprocessing catalyst business in March, 2001. The resulting joint venture, Advanced Refining Technologies (ART), focuses on new product development. It offers catalysts for distillate hydrotreating operations, from heavy VGO and demetallized oil to light naphtha applications. In addition, its hydroprocessing catalysts for residuum include fixed and ebullating bed applications.
Institut Francais de Petrole (IFP) Industrial Division and Procatalyse SA merged to form Axens on June 30, 2001. The catalyst division is referred to as Axen/Procatalyse SA and provides catalysts and adsorbents for the refining, petrochemical, and natural gas industries.
Merichem Chemicals & Refinery Services LLC, a subsidiary of the Merichem Company, acquired Gas Technology Products from US Filter, a Vivendi Company, and is now called Gas Technology Products LLC. Gas Technology Products LLC specializes in hydrogen sulfide and mercaptan removal.
ONDEO Nalco Co., Naperville, Ill., bought ExxonMobil Chemical Co.'s interest in the former Nalco/Exxon Energy Chemicals LP. The company changed the name to ONDEO Nalco Co.
Although not a merger, last year United Catalysts Inc., Louisville, Ky., changed its name to Sud Chemie Inc., adopting the name of its parent company, Sud Chemie AG of Munich, Germany.
And Degussa AG now represents catalysts formerly offered by Huls GMBH.
New technology
In the refining industry's search for clean fuels, most of the emerging technologies are catalyst-related improvements that allow refiners to keep octane during the sulfur-removal process while operating at less severe conditions.
Many of the catalyst suppliers list new products this year. Some represent new, breakthrough technology, while others replace older catalysts with improved versions and updated nomenclature.
Engelhard Corp. recently celebrated the commercialization of its new catalyst, NaphthaMax. Engelhard's Pyrochem-Plus zeolite, on a distributed matrix structure, is applied to inside and outside catalyst pores to increase selectivity during short contact time. The high activity and surface area allow an increase in liquids yields without raising temperature, pressure, or causing overcracking of FCC feed.
Instituto Mexicano del Petroleo is currently developing a new reforming catalyst specially designed for the Mexican petroleum industry. After the industrial performance evaluation is concluded, the catalyst is expected to be available for commercialization in mid-2002.
Expansion
While some catalyst companies introduced innovative technologies to meet refiner's demands, others increased catalyst manufacturing capacities to meet record-breaking refinery processing utilization, at times as high as 94.2%.
Haldor Topsoe AS, for example, started its second hydrotreating catalyst plant, located in Denmark, in 2000. The new plant will primarily serve European clients, but together with output from the Houston plant, will also cover global requirements. The combined production capacity of the facilities is now 30 million lb/year of hydrotreating catalyst.
R&D
France's IFP intends to spend some 300 million francs to create a catalyst center near its Fezin refinery in Solaize. IFP expects to employ nearly 300 scientists to develop catalysts for the refining, petrochemical, and natural gas markets. The plant is to begin operations by 2003.
