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FOCUS ON c C A T A L Y S T S 11111111111111111111lllllllllll A MONTHLY REPORT FROM ALAN E COMYNS MAY 2002 SUPERCRITICAL CO, NOT JUST FOR COFFEE In...

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ON c

C A T A L Y S T S 11111111111111111111lllllllllll A MONTHLY REPORT FROM ALAN E COMYNS MAY 2002

SUPERCRITICAL CO, NOT JUST FOR COFFEE

In this issue MARKETS AND BUSINESS

1-3

Process catalysts show healthy growth Dutch catalyst consortium COMPANY

NEWS

3-5

Millennium doubles capacity for nanotitania Novozymes developing bioethanol NEW PLANTS

5-6

GTL projects for Qatar, Peru, Australia Indian cresol/xylenol

plant

NEW TECHNOLOGY

6-7

Sumitomo updates Deacon Polyoxometallate bleaching

used for

Ethanol from straw ENVIRONMENT

7

New autocats for Jaguars PATENTS

7-6

SHELF

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CATALYSTS

CATALYSTS

Supercritical CO,, long used for decaffeinating coffee, is at last finding applications in industrial chemistry. Thomas Swann & Co have commissioned a continuous supercritical catalytic hydrogenation plant which is designed to produce 1000 ton/year of product’. The plant was engineered by Chematur, which has experience with supercritical water. Martyn Polyakoff at the University of Nottingham had done the laboratory work which led to this process. Now we have a demonstration2, from Georgia Tech and Degussa-Huls, that epoxidation by hydrogen peroxide, if conducted in SCCO,, does not need a catalyst and can proceed to completion. Epoxidation by hydrogen peroxide normally requires a catalyst, or pre-conversion of the peroxide to a peroxy-acid. But in SCCO,, peroxocarbonic acid, or its sodium salt, are believed to be involved and no additional catalyst is required. There are problems of course. The alkene needs to be water-soluble if useful yields are to be obtained. This is the first example I have seen (apart from aqueous systems) in which the supercritical medium is a reactant as well as the solvent. One wonders which other simple compounds might provide useful supercritical solvents and/or reagents. Supercritical water is a strong acid and has been used for destroying hazardous wastes. Supercritical dhane has already been used as a wt for continuous asymmetric reduc&m and for phase-transfer CATALYSTS

CATALYSTS

catalysis of alkylation. Supercritical hydrogen peroxide itself would probably be too unstable. Hydrogen sulfide might provide a route to organic sulfides. Dinitrogen tetroxide might be a useful nitrating agent, and nitrosyl chloride a nitrosating agent. Elemental chlorine, under supercritical conditions, might be a useful chlorinating agent. Would supercritical methanol be a methylating or a methoxylating agent? There is no limit to the number of reactions which might proceed better under supercritical conditions. Catalysts might or might not be needed. Now that the engineering problems have been solved, in at least one case, chemists should exercise their imaginations. Alan E. Comyns

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iAc News, 2002, (9) Industrial & Engineering Chemistry, 2002,41 316-323

(3),

A vision of the future The chemical industry in 40 years time is discussed, as seen by the author Nigel Davis. Predictions include: the key role of acetone from biomass; the use of fusion reactors for energy; the Far East is expected to dominate demand by 2040; countries with plenty of gas, in the Middle East and central Asia, are expected to dominate supply; CATALYSTS

CATALYSTS

healthcare and nutrition are expected to see many changes, including gene mapping, treatment of many diseases in the womb, new vaccines and genetically modified food. It is expected by some that 80-90% of organic chemicals will be made by bioprocesses by 2099. A more conservative view is that in 1O-l 5 years biocatalysis will provide 510% of the value of the chemical and pharmaceutical industries. European Chemical News, 1 Apr 2002,76 40,42-43

(1999)

Environment and products drive catalyst market According to the Freedonia Group, process catalyst demand will increase rapidly and reach a market value of $3.3 bn by 2005. The rise is mainly attributed to the rise of environmentfriendly refinery and chemical products. The polymerisation catalysts sector is seen to be the fastest growing segment, in which metallocene catalysts are predicted to overtake Ziegler-Natta catalysts and reaction initiators by 2010. Catalysts for R&D applications will remain a strong segment as enzyme-based and chiral catalysts become more widely utilised in pharmaceutical production. Demand for oxidation and syngas catalysts has been low for the past two years. In the USA, 45% of the catalyst market is controlled by Sud-Chemie, Atofina, UOP, Shell, Akzo Nobel, Grace Davison, and Engelhard. Process Engineering, Feb 2002, 83 (2) 19 & Hydrocarbon Processing, Feb 2002,81 (2) 21

Catalysts enjoy regulation growth New environmental legislation in the US and the EU and its effects on the catalysts sector are investigated. During 2001 Engelhard increased overall sales by 12%. Sales for process technologies were around $600 M with environmental catalysts accounting for $400 M. Sales of petrochemical catalysts rose by 810%. Refining sales and sales of environmental catalysts improved by 10%. The increasing use of GTL processes is detailed. Sales of polypropylene catalysts showed double-digit growth due mostly to increased growth of its PP catalyst 2

technology Lynx 1000. Si.id Chemie reports global refinery catalysts sales growth of 4%/y. Sales of environmental and chemicals catalysts have risen by 8%. Overall sales of catalysts by Sijd Chemie reached E375.1 M in 2001, with 33% derived from its refinery catalysts business. The company hopes to exceed 30% sales from products less than five years old. Sales of desulfurization catalysts are expected to show growth of over 10%/y for the next 2-3 years due to new regulations. Stid Chemie’s purification business has seen growth of around 10% recently. The company is collaborating with a multinational company to convert gas-to-liquids using a Fischer-Tropsch process. During 2001 Grace Davison increased sales of catalysts by 11% to $625 M with the focus on refinery chemical and environmental catalysts. The company’s refinery catalysts business is set to rise by 4-5%/y. Recent acquisitions and jvs, together with newly developed catalysts, are discussed. Sales by Axens are set to rise by 5-7%/y. The company’s PrimeG+ process for FCC gasoline desulfurization has over 50% of the market in Europe and North America. Around 8-12% of sales are attributed to R&D. Akzo Nobel reports catalysts sales of El .14 bn in 2001 including g600 M from polymers and chemicals and E541 M from refinery catalysts. Sales of refinery catalysts increased by 4% during 2001. Degussa reported a 10% rise in catalyst sales to around c300 M, with pharmaceutical catalysts rising by 8-10% and PP catalysts increasing by 5-l 0% with the focus on Asia and the Middle East. Haldor Topsoe reports a 3% rise in the consumption of hydrotreating catalysts. The company forecasts sales growth of 10%/y for the next five years. Chemical Week, 13 Mar 2002, 164 (11 (supplement)), s3-s5

Forefront of the chiral boom Frost & Sullivan estimates that revenues for chiral technology will rise by 13.4%/y, from c7.6 bn in 2000 to 618.3 bn in 2007. The pharmaceutical industry accounts for 80% of the industry’s total consumption. Synetix has set up Synetix Chiral

Technologies (SCT), which is aimed at commercialising new asymmetric chiral technologies. SCT offers technologies of chiral and achiral catalytic processes and offers it to the pharmaceutical and chemical industries. The firm has developed an immobilised version of its (R,R)(salen) Co catalyst in collaboration with Rhodia ChiRex. The firm will commercially produce the material for Rhodia ChiRex, and both firms will jointly formulate and produce immobilised catalysts intended for the production of pharmaceutical intermediates and fine chemicals. Speciality Chemicals, Mar 2002, 22 (3) 10-l 1

Prominent role for DSM within national catalyst platform The new Dutch platform for chemical catalyst research is called ACTS (Advanced Catalytic Technologies for Sustainability) and is part of a covenant agreed on 7 Feb 2002. Participants in the platform include Akzo Nobel, DSM, Engelhard, Dow, and Shell. Two projects starting this year are for energy (sustainable hydrogen) and fine chemicals. The allocation to the fine chemicals programme is g27 M in 7 years with the Dutch Ministry of Economic Affairs (EZ) contributing g4.5 M, the Nederlandse Organisatie voor Wetenschappelijk Onderzoek (NWO, Dutch Organisation for Scientific Research) c4.5 M, joint industry E4.5 M, and with matching funds from the universities. The research should provide a breakthrough in the integration of chemistry and life sciences. DSM Limburg Nieuws, 15 Mar 2002,51 (6) 1 (DSM Nieuws, Communication Support Center, Postbus 6500,640l JH Heerlen, The Netherlands)

Pharmaceutical outsourcing The use of outsourcing by Jharmaceutical manufacturers Norldwide, including the developmental stage, is discussed. Zutsourcing is often used for cGMP, xs investment in a cGMP plant could add around 30% to costs. Biocatalysis s an area requiring specialist (nowledge that is suitable for xrtsourcing. Altus Biologics of Cambridge, MA, can develop 3iocatalytic routes for customers as MAY

2002

well as supplying enzymes. Diversa is also able to create enzymes that are specifically made for individual reactions. BASF has increased its contract manufacturing business recently after it sold its pharmaceutical operations. Chemical Week, 13 Feb 2002,164 58,60

(8 (supplement)),

2002 catalyst directory The directory lists suppliers to the catalyst industry worldwide by sector. Details include company name, address, telephone, fax number, and website, together with details of the products and services supplied. ;;;_;;;I Week, 13 Mar 2002, 164 (11 (supplement)),

Chemistry and Industry (London), 18 Feb 2002, (4) 5 & Chemie Prod&ion, Mar 2002, (3) 12

Avecia and Synetix to collaborate In a collaborative venture, Avecia and Synetix Chiral Technologies will work on the development of Avecia’s transfer hydrogenation (CATHY) and cyanohydrin (CACHy) catalysts for pharmaceuticals production. Novel chiral techniques will also be investigated. European Chemical News, 11 Mar 2002,76 (1996) & Chemical Week, 13 Mar 2002,164 (11) 25

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Borealis sells PE catalysts to Grace Borealis has sold its polyethylene catalyst plant to WR Grace for an undisclosed amount. Following the sale, Borealis will switch their development work to advanced catalysts for making high performance polyolefins.

Altair Nanotechnologies reports revenue for 2001

Chemistry and industry (London), 4 Feb 2002, (3) 5

Altair Nanotechnologies has announced that revenues for the year ended Dee 2001 were about $43,000. The company expects to report revenues for 1Q ended Mar 2002 in excess of $45,000 - surpassing revenues for the entire year of 2001. Altair Nanotechnologies owns a proprietary technology for making nanocrystalline materials of unique quality, both economically and in large quantities. The company is currently developing special nanomaterials with potential applications in fuel cells, solar cells, advanced energy storage devices, thermal spray coatings, catalysts, cosmetics, paints, and environmental remediation. Press release from Altair Nanotechnologies Tel: tl 307 587 8245. Website: http://www.altairtechnologies.com or http://www.altairint.com (1 Apr 2002)

Dow launches site

known chemical companies including Akzo Nobel and Shell Chemicals.

Inc, USA.

Codexis applies biocatalysis to fine chemicals Codexis is to develop chiral catalysts and improve processes for new and existing products. It will use technology developed by its parent Maxygen to produce chirally active biological and chemical catalysts, pharmaceutical intermediates, and bulk active ingredients. Codexis envisages many applications for gene shuffling which can be used to optimize the activity of a single enzyme or a complete genome. The company believes that its technology could help solve the shortage of biopharmaceutical capacity. Chemical Market Reporter, 11 Mar 2002 (Website: http://www.chemexpo.com/cmronline)

CRI profiled Avantium and DSM strike deal Avantium has secured from DSM a 61 M contract to screen catalyst systems for DSM. This first phase may be followed by other deals. Avantium will use its in-house technology for experimentation and simulation purposes. Avantium has other collaborations with several wellMAY

2002

The CRI Catalyst Company, part of Royal Dutch Shell Group, is profiled. Details include an overview of the company with the focus on ethylene oxide catalysts, styrene catalysts, hydrogenation catalysts, and environmental catalysts and systems. ;;_;ical

Week, 13 Mar 2002, 164 (11 (supplement)),

Dow Chemical has set up a new web site (www.voractiv) to promote its new Voractiv polymers. These are the first catalytically active products in the polyurethane sector. They reduce amine emissions. Chemical Market Reporter, 11 Mar 2002, (Website: http://www.chemexpo.com/cmronline)

Chemical markets catalyst for Unipol PP Dow

Dow Chemical has launched its new Shac 330 catalyst for its Unipol polypropylene (PP) process with process control software. This a Ziegler-Natta catalyst for the production of lmppax impact copolymer grades of PP, which goes further than the Shac 310 and 320 PP catalysts. The new catalyst may result in a 15-25% increase in production, but with no capital investment. European Chemical News, 1 Apr 2002,76

(1999)

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Dowa Mining to expand precious metals recovery business In May 2002 Dowa Mining Co is to invest Yen 400-500 M in its subsidiary Nippon PGM Co, to increase its processing capacity for recovering rare metals from catalytic converters. Stricter laws on vehicle emissions may mean greater availability of metal in catalytic converters taken from junked cars, hence the company’s decision to expand recovery capacity of metals such as platinum and palladium from 450 tonne/m0 to 800 tonne/ma. Nikkei Net, 14 Mar 2002 (Website: http://www.nni.nikkei.co.jp/)

DuPont Dow expands EPDM offerings, boosts capacity DuPont Dow Elastomers is to develop, produce, and market a new range of gas-phase metallocene EPDM products under the brand name Nordel MG. The combination of metallocene technology and gas-phase production will be a first for EPDM production. The new product range will complement the existing Nordel IP range. The Elastomers Times International, 2002, (27) 1,6 (DuPont Dow Elastomers SA, PO Box CH-1218, Le Grand-Saconnex, Geneva, Switzerland. Fax: t41 22 717 4001. Website wwwdupont-dow.com.)

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