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Nanostructured resins make solid acid catalysts
F O C U S Around 38% of PTC’s business is to the drugs industry. PTC says it has been getting many inquiries from generic drug producers. The company’s technology can help save money by increasing yield, cutting cycle time, replacing expensive hazardous strong bases with cheaper organic bases, and reducing excessive reactant use. PTC has benefited from the tough economic climate, as manufacturers seek ways to cut costs. Chemical Week, 11 Feb 2004, 166 (5) (Website: http://www.chemweek.com)
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Scaleup for metal-complex ligand Hokko Chemical Industry Co has commenced in December 2003 industrial scale production of tritertiary butyl phosphine in a new facility with a potential capacity of 20-40 tonne/y. The company previously produced only gram to kilogram amounts of the ligand as a laboratory reagent. The scaleup is aimed at meeting increased demand for the ligand as a metal-complex catalyst. Chemical Engineering (New York), Feb 2004, 111 (2), 13
Wacker signs chiral alcohols deal Wacker Specialties has agreed an R&D deal with enzyme discovery firm Prokaria (Reykjavik) to develop chiral alcohol building blocks for active pharmaceutical intermediates. Prokaria will develop novel enzymes to produce the alcohols. Prokaria has exclusive rights to obtain enzymes from Iceland’s geothermal areas. Wacker also has an agreement with Jülich Fine Chemicals to develop chiral alcohols using biotechnology. Jülich will be involved in the screening and evaluation of the enzymes that Prokaria identifies. Wacker says its latest collaboration is an important move in forming a chiral alcohols “competence centre” for the drugs industry. Chemical Week, 11 Feb 2004, 166 (5) (Website: http://www.chemweek.com)
NEW PLANTS Degussa to manufacture nanoparticulate zinc oxide Degussa has developed a new technology for manufacturing nanoscale zinc oxide. The new material will be introduced through its Care Specialities business unit in 1Q 2004 for use in sunscreens. Nanoscale zinc oxide retains UV absorption properties without scattering visible light. This allows the production of transparent sunscreens. A 40 tonne/y pilot plant was started up in Hanau, Germany, in Oct 2003. A full scale commercial plant will start up in early 2006. European Chemical News, 9 Feb 2004, 80 (2086), 19
APRIL 2004
Second GTL project gets green light Qatar Petroleum has collaborated with Shell to develop a 140,000 bbl/day gas-to-liquids facility at Ras Laffan, based on Shell’s proprietary GTL technology. The project will be built in two stages, with the first 70,000 bbl/day to be commissioned in 2009, and the second, similar section to come onstream in 2011. EPC contracts will be awarded in late 2005 while front-end engineering and design will commence in 2004.
NEW TECHNOLOGY Small crystal-size zeolite beta developed Sinopec Fushun Research Institute of Petroleum and Petrochemicals has developed a small crystal-size zeolite beta. Features of the new catalytic material are low acidity, small acid site number, high silicon/aluminium ratio, high crystallinity, and numerous secondary pores. It has a unique preparation process, stable product properties, and strong application prospects. Three grades of small crystal-size zeolite beta having different features have been developed as new generation hydrocracking catalysts. The three catalysts are: FC-14 single stage high pressure hydrocracking catalysts, FC14 middle distillate oriented high pressure hydrocracking catalyst, and FC-20 high pressure hydrocracking or diesel hydromodification isomerisation freezing point reducing catalyst. China Chemical Reporter, 16 Feb 2004, 15 (5), 13
Nitrogen and Methanol, Jan/Feb 2004, (267), 11
Methanol-to-propylene demonstrator starts up Lurgi’s process has been employed at Borealis’ demonstrator plant in Tjelbergodden, Norway, to yield propylene from natural gas. The demonstrator facility utilises methanol from the nearby Statoil methanol plant as feedstock. Statoil owns 50% of Borealis while OMV and the Abu Dhabi-based International Petroleum Investment Co holds the remainder.
Coated titania photocatalysts Titania photocatalysts for exterior use are usually coated with apatite, but this is not acid-resistant and may be damaged by acid rain. The National Institute of Advanced Sciences and Technology in Japan, together with Toumei, have developed a similar product, coated with fluorapatite, which is acid-resistant. Japan Chemical Week, 19 Feb 2003, 45 (2258), 7
Nitrogen and Methanol, Jan/Feb 2004, (267), 10
ExxonMobil starts up new plant at Baton Rouge ExxonMobil Chemical has brought onstream a new unit which uses proprietary technology to produce metallocene ethylene elastomers at Baton Rouge, LA. The plant, reported to be the first of its kind, has capacity in excess of 90,000 ton/y. Chemical Market Reporter, 23 Feb 2003 (Website: http://www.chemicalmarketreporter.com)
Nanostructured resins make solid acid catalysts A longstanding challenge to catalyst developers has been the generation of solid state acidity within a porous network having pores larger than those of zeolites. Workers at the University of Colorado have achieved this by polymerising a liquid crystal containing both carboxylic and sulfonic acid groups. The new material, having nanometre-sized channels, was very effective in
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F O C U S catalysing the esterification of benzyl alcohol with 1-hexanoic acid. Chemical & Engineering News, 1 Mar 2004, 82 (9), 36 & Journal of The American Chemical Society, 2004, 126, 1616
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Some properties and advantages of the products are indicated. Commercial production should start in 2H 2004 by converting existing facilities. Dow is developing the copolymers in conjunction with customers.
Combinatorial process yields new isomerisation catalyst
European Chemical News, 1 Mar 2004, 80 (2089), 24 & Plastics and Rubber Weekly, 20 Feb 2004, 9
UOP and Sintef (Norway) have developed a combinatorial toolbox which includes both (heterogeneous) catalyst production and testing. Using this, UOP has developed a superior catalyst for its Para-Isom process for making low-sulfur, high-octane gasoline. This has been successfully tested at Big West Oil’s refinery at North Salt Lake City.
Novozymes reduces cost of cellulase twelvefold
catalyst based on carbon fibres made from pitch which will catalyse the oxidation of SO2 to SO3 at room temperatures. Addition of water converts the SO3 to sulfuric acid. The new catalyst will be manufactured from Oct 2004 by OMviro Co, a jv based in Osaka. Japan Chemical Week, 19 Feb 2003, 45 (2258), 7
Chemical Engineering (New York), Feb 2004, 111 (2), 13
New catalyst upgrades vacuum gasoils Akzo Nobel’s NEBULA catalyst range is said to be highly efficient in pretreatment uses for hydrocracking. NEBULA 20 is claimed to enhance hydrocarbon feed’s for FCC units and can cut FCC feeds sulfur content to 190 ppm from 1.9 wt%, based on pilot-plant testing. Pre-treating FCC feed significantly reduces the amount of sulfur in FCC product pool and allows refiners to achieve the lowsulfur requirement of 10 ppm. Hydrocarbon Processing, Feb 2004, 83 (2), 26
Ultra-low sulfur gasoline for fuel cells Hydrogen for fuel cells can be made from gasoline, but it must contain less than about 20 ppb of sulfur to avoid poisoning the catalyst. The National Institute of Advanced Industrial Science and Technology, Tsukuba, has developed a hydrotreating catalyst for making this ultra-low sulfur gasoline from regular gasoline. The catalyst contains nano-particles of a palladium-platinum alloy on a stabilised Y-zeolite. Chemical Engineering (New York), Feb 2004, 111 (2), 17
Dow has more Insite Dow Chemical has modified its Insite technology by using new catalysts to make the Versify series of speciality propylene-ethylene copolymers.
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Novozymes Biotech, working under a contract from the National Renewable Energy Laboratory, has reduced the manufacturing cost of cellulase (which converts cellulose to glucose) by a factor of twelve. This in turn should reduce the cost of making one gallon of bio-ethanol from >$5.00 to <50 cents. Further major cost reductions should be possible. Chemical & Engineering News, 16 Feb 2004, 82 (7), 12 & Chemical Week, 18 Feb 2004, 166 (6) (Website: http://www.chemweek.com) & Chemical Market Reporter, 16 Feb 2004 (Website: http://www.chemicalmarketreporter.com) & Dagbladet Borsen, 9 Feb 2004 (in Danish) & Chemische Rundschau, 24 Feb 2004, (2), 56 (in German)
Successful trial run of the indirect coal liquefaction catalyst unit Yanzhou Coal Mine Group has completed a 10,000 tonne/y pilot catalyst unit to complement its 10,000 tonne/y indirect coal liquefaction project at Lunan Chemical Fertilizer Plant in China. Successful production commenced on 5 Dec 2003. China Chemical Reporter, 26 Jan/6 Feb 2004, 15 (3/4), 13
Engelhard targets pharma A new line of high-purity homogenous catalysts is being launched by Engelhard for early pharmaceutical development. The company is expanding catalyst supply from a custom basis to the broader market, in order to grow its presence in the pharmaceutical sector. Chemical Week, 4 Feb 2004, 166 (4), 24
ENVIRONMENT Ambient FGD using carbon fibres Mitsubishi Heavy Industries and Osaka Gas have developed a fibrous
Oxonica improves diesel combustion Oxonica, a UK startup company, has developed a catalyst to enhance the combustion of diesel in engines that allows the production of more energy whilst significantly reducing the emission of hydrocarbons and particles. Diesel consumption can also be reduced by 10%. The additive, Envirox, is formulated using nanoparticles of cerium dioxide. The additive has undergone a 6 month testing period in 80 buses in Hong Kong and is now being tested by the UK bus company Stagecoach. European Chemical News, 9 Feb 2004, 80 (2086), 17 & Chimie Pharma Hebdo, 9 Feb 2004, (244), 17 (in French)
Fuel oil-reforming catalyst for automobiles slashes soot, PM Nippan Kenkyujo Co (Yokohama) has developed a fuel oil reforming catalyst for automotive applications. The product, which is added to the fuel tank, reduces soot and PM emissions. It is being marketed in Japan by Gojyo Sangyo (Tokyo). There is a detailed discussion of the product and its applications. Japan Chemical Week, 5 Feb 2004, 45 (2256), 2
Ecocat to sell Metpela to Godarb AB Sweden Ecocat Oy has sold its shares in subsidiary Metpela Oy to Godarb AB. Ecocat makes catalytic converters at Vihtavouri. Metpela makes exhaust systems. Ecocat will focus more specifically on solutions connected to the use of catalysts in petrol and diesel engines. Ecocat had sales of €34 M in 2002 and employs 162, excluding Metpela. Press release from Ecocat Oy, Laukaa, Finland. Tel: 358 (0)10 861 717 (27 Jan 2004)
APRIL 2004
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Scaleup for metal-complex ligand Hokko Chemical Industry Co has commenced in December 2003 industrial scale production of tritertiary butyl phosphine in a new facility with a potential capacity of 20-40 tonne/y. The company previously produced only gram to kilogram amounts of the ligand as a laboratory reagent. The scaleup is aimed at meeting increased demand for the ligand as a metal-complex catalyst. Chemical Engineering (New York), Feb 2004, 111 (2), 13
Wacker signs chiral alcohols deal Wacker Specialties has agreed an R&D deal with enzyme discovery firm Prokaria (Reykjavik) to develop chiral alcohol building blocks for active pharmaceutical intermediates. Prokaria will develop novel enzymes to produce the alcohols. Prokaria has exclusive rights to obtain enzymes from Iceland’s geothermal areas. Wacker also has an agreement with Jülich Fine Chemicals to develop chiral alcohols using biotechnology. Jülich will be involved in the screening and evaluation of the enzymes that Prokaria identifies. Wacker says its latest collaboration is an important move in forming a chiral alcohols “competence centre” for the drugs industry. Chemical Week, 11 Feb 2004, 166 (5) (Website: http://www.chemweek.com)
NEW PLANTS Degussa to manufacture nanoparticulate zinc oxide Degussa has developed a new technology for manufacturing nanoscale zinc oxide. The new material will be introduced through its Care Specialities business unit in 1Q 2004 for use in sunscreens. Nanoscale zinc oxide retains UV absorption properties without scattering visible light. This allows the production of transparent sunscreens. A 40 tonne/y pilot plant was started up in Hanau, Germany, in Oct 2003. A full scale commercial plant will start up in early 2006. European Chemical News, 9 Feb 2004, 80 (2086), 19
APRIL 2004
Second GTL project gets green light Qatar Petroleum has collaborated with Shell to develop a 140,000 bbl/day gas-to-liquids facility at Ras Laffan, based on Shell’s proprietary GTL technology. The project will be built in two stages, with the first 70,000 bbl/day to be commissioned in 2009, and the second, similar section to come onstream in 2011. EPC contracts will be awarded in late 2005 while front-end engineering and design will commence in 2004.
NEW TECHNOLOGY Small crystal-size zeolite beta developed Sinopec Fushun Research Institute of Petroleum and Petrochemicals has developed a small crystal-size zeolite beta. Features of the new catalytic material are low acidity, small acid site number, high silicon/aluminium ratio, high crystallinity, and numerous secondary pores. It has a unique preparation process, stable product properties, and strong application prospects. Three grades of small crystal-size zeolite beta having different features have been developed as new generation hydrocracking catalysts. The three catalysts are: FC-14 single stage high pressure hydrocracking catalysts, FC14 middle distillate oriented high pressure hydrocracking catalyst, and FC-20 high pressure hydrocracking or diesel hydromodification isomerisation freezing point reducing catalyst. China Chemical Reporter, 16 Feb 2004, 15 (5), 13
Nitrogen and Methanol, Jan/Feb 2004, (267), 11
Methanol-to-propylene demonstrator starts up Lurgi’s process has been employed at Borealis’ demonstrator plant in Tjelbergodden, Norway, to yield propylene from natural gas. The demonstrator facility utilises methanol from the nearby Statoil methanol plant as feedstock. Statoil owns 50% of Borealis while OMV and the Abu Dhabi-based International Petroleum Investment Co holds the remainder.
Coated titania photocatalysts Titania photocatalysts for exterior use are usually coated with apatite, but this is not acid-resistant and may be damaged by acid rain. The National Institute of Advanced Sciences and Technology in Japan, together with Toumei, have developed a similar product, coated with fluorapatite, which is acid-resistant. Japan Chemical Week, 19 Feb 2003, 45 (2258), 7
Nitrogen and Methanol, Jan/Feb 2004, (267), 10
ExxonMobil starts up new plant at Baton Rouge ExxonMobil Chemical has brought onstream a new unit which uses proprietary technology to produce metallocene ethylene elastomers at Baton Rouge, LA. The plant, reported to be the first of its kind, has capacity in excess of 90,000 ton/y. Chemical Market Reporter, 23 Feb 2003 (Website: http://www.chemicalmarketreporter.com)
Nanostructured resins make solid acid catalysts A longstanding challenge to catalyst developers has been the generation of solid state acidity within a porous network having pores larger than those of zeolites. Workers at the University of Colorado have achieved this by polymerising a liquid crystal containing both carboxylic and sulfonic acid groups. The new material, having nanometre-sized channels, was very effective in
5
F O C U S catalysing the esterification of benzyl alcohol with 1-hexanoic acid. Chemical & Engineering News, 1 Mar 2004, 82 (9), 36 & Journal of The American Chemical Society, 2004, 126, 1616
O N
C ATA LY S T S
Some properties and advantages of the products are indicated. Commercial production should start in 2H 2004 by converting existing facilities. Dow is developing the copolymers in conjunction with customers.
Combinatorial process yields new isomerisation catalyst
European Chemical News, 1 Mar 2004, 80 (2089), 24 & Plastics and Rubber Weekly, 20 Feb 2004, 9
UOP and Sintef (Norway) have developed a combinatorial toolbox which includes both (heterogeneous) catalyst production and testing. Using this, UOP has developed a superior catalyst for its Para-Isom process for making low-sulfur, high-octane gasoline. This has been successfully tested at Big West Oil’s refinery at North Salt Lake City.
Novozymes reduces cost of cellulase twelvefold
catalyst based on carbon fibres made from pitch which will catalyse the oxidation of SO2 to SO3 at room temperatures. Addition of water converts the SO3 to sulfuric acid. The new catalyst will be manufactured from Oct 2004 by OMviro Co, a jv based in Osaka. Japan Chemical Week, 19 Feb 2003, 45 (2258), 7
Chemical Engineering (New York), Feb 2004, 111 (2), 13
New catalyst upgrades vacuum gasoils Akzo Nobel’s NEBULA catalyst range is said to be highly efficient in pretreatment uses for hydrocracking. NEBULA 20 is claimed to enhance hydrocarbon feed’s for FCC units and can cut FCC feeds sulfur content to 190 ppm from 1.9 wt%, based on pilot-plant testing. Pre-treating FCC feed significantly reduces the amount of sulfur in FCC product pool and allows refiners to achieve the lowsulfur requirement of 10 ppm. Hydrocarbon Processing, Feb 2004, 83 (2), 26
Ultra-low sulfur gasoline for fuel cells Hydrogen for fuel cells can be made from gasoline, but it must contain less than about 20 ppb of sulfur to avoid poisoning the catalyst. The National Institute of Advanced Industrial Science and Technology, Tsukuba, has developed a hydrotreating catalyst for making this ultra-low sulfur gasoline from regular gasoline. The catalyst contains nano-particles of a palladium-platinum alloy on a stabilised Y-zeolite. Chemical Engineering (New York), Feb 2004, 111 (2), 17
Dow has more Insite Dow Chemical has modified its Insite technology by using new catalysts to make the Versify series of speciality propylene-ethylene copolymers.
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Novozymes Biotech, working under a contract from the National Renewable Energy Laboratory, has reduced the manufacturing cost of cellulase (which converts cellulose to glucose) by a factor of twelve. This in turn should reduce the cost of making one gallon of bio-ethanol from >$5.00 to <50 cents. Further major cost reductions should be possible. Chemical & Engineering News, 16 Feb 2004, 82 (7), 12 & Chemical Week, 18 Feb 2004, 166 (6) (Website: http://www.chemweek.com) & Chemical Market Reporter, 16 Feb 2004 (Website: http://www.chemicalmarketreporter.com) & Dagbladet Borsen, 9 Feb 2004 (in Danish) & Chemische Rundschau, 24 Feb 2004, (2), 56 (in German)
Successful trial run of the indirect coal liquefaction catalyst unit Yanzhou Coal Mine Group has completed a 10,000 tonne/y pilot catalyst unit to complement its 10,000 tonne/y indirect coal liquefaction project at Lunan Chemical Fertilizer Plant in China. Successful production commenced on 5 Dec 2003. China Chemical Reporter, 26 Jan/6 Feb 2004, 15 (3/4), 13
Engelhard targets pharma A new line of high-purity homogenous catalysts is being launched by Engelhard for early pharmaceutical development. The company is expanding catalyst supply from a custom basis to the broader market, in order to grow its presence in the pharmaceutical sector. Chemical Week, 4 Feb 2004, 166 (4), 24
ENVIRONMENT Ambient FGD using carbon fibres Mitsubishi Heavy Industries and Osaka Gas have developed a fibrous
Oxonica improves diesel combustion Oxonica, a UK startup company, has developed a catalyst to enhance the combustion of diesel in engines that allows the production of more energy whilst significantly reducing the emission of hydrocarbons and particles. Diesel consumption can also be reduced by 10%. The additive, Envirox, is formulated using nanoparticles of cerium dioxide. The additive has undergone a 6 month testing period in 80 buses in Hong Kong and is now being tested by the UK bus company Stagecoach. European Chemical News, 9 Feb 2004, 80 (2086), 17 & Chimie Pharma Hebdo, 9 Feb 2004, (244), 17 (in French)
Fuel oil-reforming catalyst for automobiles slashes soot, PM Nippan Kenkyujo Co (Yokohama) has developed a fuel oil reforming catalyst for automotive applications. The product, which is added to the fuel tank, reduces soot and PM emissions. It is being marketed in Japan by Gojyo Sangyo (Tokyo). There is a detailed discussion of the product and its applications. Japan Chemical Week, 5 Feb 2004, 45 (2256), 2
Ecocat to sell Metpela to Godarb AB Sweden Ecocat Oy has sold its shares in subsidiary Metpela Oy to Godarb AB. Ecocat makes catalytic converters at Vihtavouri. Metpela makes exhaust systems. Ecocat will focus more specifically on solutions connected to the use of catalysts in petrol and diesel engines. Ecocat had sales of €34 M in 2002 and employs 162, excluding Metpela. Press release from Ecocat Oy, Laukaa, Finland. Tel: 358 (0)10 861 717 (27 Jan 2004)
APRIL 2004