- Email: [email protected]
A history of the british catalyst industry: part 1
FOCUS ON C A T A L Y S T S A MONTHLY REPORT FROM ALAN E COMYNS MARCH 2012
A HISTORY OF THE BRITISH CATALYST INDUSTRY: PART 1
In this issue
MARKETS AND BUSINESS
2-3
World enzymes forecast Japanese catalyst output up 6%
COMPANY NEWS
3-5
BASF to exit plant biotech in Europe DSM to enter biofuels Rhodia to obtain lanthanides from China
NEW PLANTS
5-7
Albemarle expands PE catalyst manufacture in LA
NEW TECHNOLOGY
7
Biofuels from seaweed New uses for by-product glycerol
PATENTS
AN INTERNATIONAL NEWSLETTER MONITORING TECHNICAL AND COMMERCIAL DEVELOPMENTS IN THE MANUFACTURE AND USE OF CATALYSTS ISSN 1351–4180
7-8
BOOKSHELF
8
EVENTS
8
These brief notes attempt a ramble through the UK catalyst industry to open a window on the historical and complex nature of catalysis in the UK, with views of the oil and catalyst industries, which will never be seen again. Catalysis is commercially attractive as the returns to the operator of an active process catalyst eclipse the catalyst costs; therefore the developer obtains attractive margins. The commercial returns and market sizes can attract organisations with an insufficient understanding of the complex technologies and commerce surrounding catalysis and this aspect is in part responsible for the demise of UK catalysis in a market that takes no hostages. In the late 1930s a development and commercial agreement was set up between IG Farben of Germany, MW Kellogg, Standard Oil New Jersey, and Standard Oil Indiana, to initiate rapid development of refining technologies and in particular the Cat Cracking technology of IGF. The Anglo Iranian Oil Company (AIOC) applied to join and was admitted to the group and developed Peter Spence HDS catalysts. In 1940, Shell, Standard Jersey, Texaco, Standard Indiana, UOP, and Kellogg agreed to pool patents and resources and set up CRA Inc, with a special company owned by Shell and Standard Jersey (Exxon), to handle business outside the USA. AIOC was not admitted as a partner as its technology was considered inferior to that of CRA members. In 1942 the six CRA
companies set up the International Catalytic Oil Processes Corp to grant to UOP and Kellogg the ability to license the catalytic refining technology descending from the 1930’s agreements. In the post war period UOP formed a joint company with Johnson Matthey to produce primarily UOP licensed platinum-containing naphtha reforming catalysts. This company was Universal Matthey Products Ltd (UMP), located in Enfield/Brimsdown next door to the JM Pt refining site. In later years UMP included manufacturing facilities in France for catalysts and oilfield chemicals. The management of UMP followed JM traditions with three tiers of lunch dining rooms, with the senior and middle managers enjoying fourcourse waitress-served lunches, personal silver napkin rings and gold edged business cards. On the shoulders of the UOP reputation, UMP widened its horizons providing development and manufacturing facilities for non-UOP technologies and catalysts. In the UK these included mordenite-based Catalytic Dewaxing for BP ventures, ICI and European refinery catalyst developments, MOD devices, UK Gas Board Fluid Bed and Gas Recycle Hydrogenator (FBH&GRH) processes, xylenols catalysts, and a range of smaller scale developments. To support an agreement with TOTAL, covering refinery chemicals, the company had a wide range of pilot plants in Brimsdown and strong links to ICI oilfields division. With its
CATALYSTS CATALYSTS CATALYSTS CATALYSTS CATALYSTS CATALYSTS
FOCUS catalyst and chemicals activities, and UOP/JM associations, UMP enjoyed a unique position until the JM banking fiasco in the 1980s when the company became 100% UOP. The Peter Spence Company played an important role in the history of UK catalysts. The company was founded to produce aluminium based chemicals for water treatment and in the 1940s saw opportunities in the transfer of its aluminium hydroxide technology to the catalyst industry. Between 1945 and 1960 the company produced a range of refining catalysts including silica-alumina for catalytic cracking, HDS, alumina, and nickelalumina, and were internationally active. The company also produced the BP selective hydrogenation catalyst, based on nickel formate, alumina supports, and some early work on auto emission catalysts, and was the major UK refining catalyst manufacturer. The company was taken over by Laporte Industries in the early 1960s and whilst Laporte continued in the catalyst business the emphasis shifted towards silica-alumina and specifically zeolite molecular sieves, promoted by their association with UOP who had developed a range of processes for refinery and chemicals separations: Sorbex, Parex, Molex, Udex, etc. Laporte went on to develop a good mordenite, probably because they cleaned it up with sulphuric (not hydrochloric) acid, and when Norton, USA, ceased production of ‘selfbonded mordenite’ for catalytic dewaxing the Laporte mordenite was a candidate to replace the supply. The application never came to fruition as Allied Signal (UOP) and Union Carbide formed a jv essentially forcing Laporte out of the market. Judging from the reception to the announcement at the NPRA by Laporte management, the deal was a complete surprise and effectively sealed the fate of this business activity. Pickford Holland gave birth to another UK catalyst manufacturer of note. Pickford Holland was a refractory manufacturer, based in Sheffield, with associations to the UK Gas Board research group. The group had developed a nickel-urania steam reforming catalyst and turned to Pickford Holland to further develop and manufacture in commercial quantities, which they did. Pickford
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ON
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Holland was bought out by another Sheffield ceramics producer – J Dyson – and Dycat catalysts came into being as a manufacturer of refinery steam reforming catalysts. Dycat further developed a nickellanthanum formulation and, with the benefit of a very active and able sales team, these catalysts were accepted and used internationally. The technology however proved to be unattractive to a ceramics mindset and Dycat was eventually traded off in return for ceramic wool. To be continued.
25 M gallon/y commercial-scale plant in 2012. To date, Valero has also made investments in Darling International’s Diamond Green Diesel project, Mascoma Corp, Solix Biosystems, Mission NewEnergy Ltd, Algenol LLC, Enerkem Inc, and Qteros Inc.
Guest editorial from Dr Andrew Holt, Catal International, Sheffield, UK E-mail: [email protected]
Codexis Inc, Solazyme Inc, Gevo Inc, Amyris Fuels LLC and KiOR Inc are among the biorefining companies that have conducted successful initial public offerings (IPOs) in 2011. The string of IPOs has paved the way for the biorefining sector to carry out major expansions in commercial production. In 2012, over 24 companies have lined up significant undertakings. Several companies will build demonstration-scale facilities to test their technologies. Some will launch commercial-scale projects, with a number of companies starting up commercial-scale production. The joint 10 ktonne/y bio-based succinic acid plant of DSM NV and Roquette Frères is slated to come online by 4Q 2012. The companies are building the plant close to Roquette’s current plant in Cassano Spinola, Italy.
MARKETS AND BUSINESS World enzymes to 2015 (Ref: 2824) An industry study with forecasts for 2015 and 2020. World enzyme demand is forecast to rise by 6.8% per year to $8 billion in 2015. 375 pp. Price $6100 (also sold in sections). Freedonia Group, 767 Beta Drive, Cleveland, OH 44143-2326, tel: +44 (0)684 9600, website: http://www.freedoniagroup.com (Dec 2011)
Betting on biorefining Independent petroleum firm Valero Energy Corp has invested in various biorefining operations, which are focused on producing a wide range of fuels. One biorefining company that received funding from Valero is Terrabon Inc. The firm is now concentrating efforts on scaling up a technology that allows fermentation of biomass feedstock, mainly municipal solid waste, into organic acids that can be further processed into chemicals and fuels. Terrabon established in 2009 a 150,000 gallon/y demonstration plant and aims to bring on stream a 5 M gallon/y commercial plant by 2013. Valero is also an investor in ZeaChem Inc, which employs a specialized microorganism to produce a variety of chemicals and fuels from biomass. The company is now setting up a 250,000 gallon/y demonstration unit, and intends to start development of a
Original Source: Biorefining Magazine, Nov 2011 (Website: http://www.biorefiningmagazine.com) © BBI International 2011
Biorefining sector poised for commercial scale-up
Original Source: Biorefining Magazine, Dec 2011 (Website: http://www.biorefiningmagazine.com) © BBI International 2011
Japanese catalyst output and shipments rallying after two-year plunge Japan’s catalyst output in Jan-Oct 2011 was up 6% year on year to 89,153 tonnes, while shipments rose 4% to 84,006 tonnes, based on a report from the Japan Catalyst Manufacturers Association using Ministry of Economy, Trade and Industry trade statistics. Shipment value increased by 11% to Yen 260.3 bn ($3.4 bn). A 40% jump in values was respectively seen in the oil refining and petrochemical production applications, buoyed by higher material costs. A table presents production and shipment volumes of catalysts, by application, in Jan-Oct 2011. Original Source: Japan Chemical Web, 16 Jan 2012 (Website: http://www.japanchemicalweb.jp) © The Chemical Daily Co Ltd 2012
MARCH 2012
A HISTORY OF THE BRITISH CATALYST INDUSTRY: PART 1
In this issue
MARKETS AND BUSINESS
2-3
World enzymes forecast Japanese catalyst output up 6%
COMPANY NEWS
3-5
BASF to exit plant biotech in Europe DSM to enter biofuels Rhodia to obtain lanthanides from China
NEW PLANTS
5-7
Albemarle expands PE catalyst manufacture in LA
NEW TECHNOLOGY
7
Biofuels from seaweed New uses for by-product glycerol
PATENTS
AN INTERNATIONAL NEWSLETTER MONITORING TECHNICAL AND COMMERCIAL DEVELOPMENTS IN THE MANUFACTURE AND USE OF CATALYSTS ISSN 1351–4180
7-8
BOOKSHELF
8
EVENTS
8
These brief notes attempt a ramble through the UK catalyst industry to open a window on the historical and complex nature of catalysis in the UK, with views of the oil and catalyst industries, which will never be seen again. Catalysis is commercially attractive as the returns to the operator of an active process catalyst eclipse the catalyst costs; therefore the developer obtains attractive margins. The commercial returns and market sizes can attract organisations with an insufficient understanding of the complex technologies and commerce surrounding catalysis and this aspect is in part responsible for the demise of UK catalysis in a market that takes no hostages. In the late 1930s a development and commercial agreement was set up between IG Farben of Germany, MW Kellogg, Standard Oil New Jersey, and Standard Oil Indiana, to initiate rapid development of refining technologies and in particular the Cat Cracking technology of IGF. The Anglo Iranian Oil Company (AIOC) applied to join and was admitted to the group and developed Peter Spence HDS catalysts. In 1940, Shell, Standard Jersey, Texaco, Standard Indiana, UOP, and Kellogg agreed to pool patents and resources and set up CRA Inc, with a special company owned by Shell and Standard Jersey (Exxon), to handle business outside the USA. AIOC was not admitted as a partner as its technology was considered inferior to that of CRA members. In 1942 the six CRA
companies set up the International Catalytic Oil Processes Corp to grant to UOP and Kellogg the ability to license the catalytic refining technology descending from the 1930’s agreements. In the post war period UOP formed a joint company with Johnson Matthey to produce primarily UOP licensed platinum-containing naphtha reforming catalysts. This company was Universal Matthey Products Ltd (UMP), located in Enfield/Brimsdown next door to the JM Pt refining site. In later years UMP included manufacturing facilities in France for catalysts and oilfield chemicals. The management of UMP followed JM traditions with three tiers of lunch dining rooms, with the senior and middle managers enjoying fourcourse waitress-served lunches, personal silver napkin rings and gold edged business cards. On the shoulders of the UOP reputation, UMP widened its horizons providing development and manufacturing facilities for non-UOP technologies and catalysts. In the UK these included mordenite-based Catalytic Dewaxing for BP ventures, ICI and European refinery catalyst developments, MOD devices, UK Gas Board Fluid Bed and Gas Recycle Hydrogenator (FBH&GRH) processes, xylenols catalysts, and a range of smaller scale developments. To support an agreement with TOTAL, covering refinery chemicals, the company had a wide range of pilot plants in Brimsdown and strong links to ICI oilfields division. With its
CATALYSTS CATALYSTS CATALYSTS CATALYSTS CATALYSTS CATALYSTS
FOCUS catalyst and chemicals activities, and UOP/JM associations, UMP enjoyed a unique position until the JM banking fiasco in the 1980s when the company became 100% UOP. The Peter Spence Company played an important role in the history of UK catalysts. The company was founded to produce aluminium based chemicals for water treatment and in the 1940s saw opportunities in the transfer of its aluminium hydroxide technology to the catalyst industry. Between 1945 and 1960 the company produced a range of refining catalysts including silica-alumina for catalytic cracking, HDS, alumina, and nickelalumina, and were internationally active. The company also produced the BP selective hydrogenation catalyst, based on nickel formate, alumina supports, and some early work on auto emission catalysts, and was the major UK refining catalyst manufacturer. The company was taken over by Laporte Industries in the early 1960s and whilst Laporte continued in the catalyst business the emphasis shifted towards silica-alumina and specifically zeolite molecular sieves, promoted by their association with UOP who had developed a range of processes for refinery and chemicals separations: Sorbex, Parex, Molex, Udex, etc. Laporte went on to develop a good mordenite, probably because they cleaned it up with sulphuric (not hydrochloric) acid, and when Norton, USA, ceased production of ‘selfbonded mordenite’ for catalytic dewaxing the Laporte mordenite was a candidate to replace the supply. The application never came to fruition as Allied Signal (UOP) and Union Carbide formed a jv essentially forcing Laporte out of the market. Judging from the reception to the announcement at the NPRA by Laporte management, the deal was a complete surprise and effectively sealed the fate of this business activity. Pickford Holland gave birth to another UK catalyst manufacturer of note. Pickford Holland was a refractory manufacturer, based in Sheffield, with associations to the UK Gas Board research group. The group had developed a nickel-urania steam reforming catalyst and turned to Pickford Holland to further develop and manufacture in commercial quantities, which they did. Pickford
2
ON
C ATA LY S T S
Holland was bought out by another Sheffield ceramics producer – J Dyson – and Dycat catalysts came into being as a manufacturer of refinery steam reforming catalysts. Dycat further developed a nickellanthanum formulation and, with the benefit of a very active and able sales team, these catalysts were accepted and used internationally. The technology however proved to be unattractive to a ceramics mindset and Dycat was eventually traded off in return for ceramic wool. To be continued.
25 M gallon/y commercial-scale plant in 2012. To date, Valero has also made investments in Darling International’s Diamond Green Diesel project, Mascoma Corp, Solix Biosystems, Mission NewEnergy Ltd, Algenol LLC, Enerkem Inc, and Qteros Inc.
Guest editorial from Dr Andrew Holt, Catal International, Sheffield, UK E-mail: [email protected]
Codexis Inc, Solazyme Inc, Gevo Inc, Amyris Fuels LLC and KiOR Inc are among the biorefining companies that have conducted successful initial public offerings (IPOs) in 2011. The string of IPOs has paved the way for the biorefining sector to carry out major expansions in commercial production. In 2012, over 24 companies have lined up significant undertakings. Several companies will build demonstration-scale facilities to test their technologies. Some will launch commercial-scale projects, with a number of companies starting up commercial-scale production. The joint 10 ktonne/y bio-based succinic acid plant of DSM NV and Roquette Frères is slated to come online by 4Q 2012. The companies are building the plant close to Roquette’s current plant in Cassano Spinola, Italy.
MARKETS AND BUSINESS World enzymes to 2015 (Ref: 2824) An industry study with forecasts for 2015 and 2020. World enzyme demand is forecast to rise by 6.8% per year to $8 billion in 2015. 375 pp. Price $6100 (also sold in sections). Freedonia Group, 767 Beta Drive, Cleveland, OH 44143-2326, tel: +44 (0)684 9600, website: http://www.freedoniagroup.com (Dec 2011)
Betting on biorefining Independent petroleum firm Valero Energy Corp has invested in various biorefining operations, which are focused on producing a wide range of fuels. One biorefining company that received funding from Valero is Terrabon Inc. The firm is now concentrating efforts on scaling up a technology that allows fermentation of biomass feedstock, mainly municipal solid waste, into organic acids that can be further processed into chemicals and fuels. Terrabon established in 2009 a 150,000 gallon/y demonstration plant and aims to bring on stream a 5 M gallon/y commercial plant by 2013. Valero is also an investor in ZeaChem Inc, which employs a specialized microorganism to produce a variety of chemicals and fuels from biomass. The company is now setting up a 250,000 gallon/y demonstration unit, and intends to start development of a
Original Source: Biorefining Magazine, Nov 2011 (Website: http://www.biorefiningmagazine.com) © BBI International 2011
Biorefining sector poised for commercial scale-up
Original Source: Biorefining Magazine, Dec 2011 (Website: http://www.biorefiningmagazine.com) © BBI International 2011
Japanese catalyst output and shipments rallying after two-year plunge Japan’s catalyst output in Jan-Oct 2011 was up 6% year on year to 89,153 tonnes, while shipments rose 4% to 84,006 tonnes, based on a report from the Japan Catalyst Manufacturers Association using Ministry of Economy, Trade and Industry trade statistics. Shipment value increased by 11% to Yen 260.3 bn ($3.4 bn). A 40% jump in values was respectively seen in the oil refining and petrochemical production applications, buoyed by higher material costs. A table presents production and shipment volumes of catalysts, by application, in Jan-Oct 2011. Original Source: Japan Chemical Web, 16 Jan 2012 (Website: http://www.japanchemicalweb.jp) © The Chemical Daily Co Ltd 2012
MARCH 2012