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Cheaper and Alternative Routes
The chemical and polymer industries are continuously seeking lower cost routes to existing products through numerous approaches: by modifying catalysts, through process re-engineering (process intensification) and reducing energy consumption. In addition, producers seek cost improvements through technology innovation, which are needed throughout all phases of R&D, production and distribution (the value chain). Last but not least, they seek to replace older technologies by using cheaper or alternative feedstocks. Classical examples are (1) propane to acrylonitrile and (2) butane to MA.
To assist clients' focus on these new routes, The Catalyst Group is initiating a new multi-client study "Feedstocks to Chemicals and Polymers: Cheaper and Alternative Routes." This new study will explore and update clients on a variety of practical new technologies being examined in the pilot plant stage, for feasibility to replace older technologies based on cost improvements emanating from using cheaper or alternative feedstocks.
Objectives and Scope
Our study will examine and identify field pilot trials of some key new technologies that may dramatically impact the cost of future production routes. This study will be conducted globally, as often innovation comes from unexpected sources, based on local trigger events. Let us document four (4) real examples under development that will be included in the report, to provide an example of the scope.
Example 1 - Methanex/Synetix Advanced GHR Trial
In Motunui, New Zealand, Methanex is testing a new advanced Synetix advanced gas-heated reforming (AGHR) reactor that if successful will allow the doubling of worldscale production and at least a 15% reduction in the cost of methanol. It was commissioned in October, 2001 for trial. What impacts can this have?
Example 2 - Novosibirsk Zeoforming Process
The first 40,000 mt/yr unit constructed by Lurgi has been operating at the Gilmar Refinery in Poland since February 1997. Two additional plants are under design, targeted for the Ukraine and Georgia. The Zeoforming process converts olefins containing gases and secondary refining fractions into high-octane gasoline and LPG, with less than 1% benzene and low sulfur and is a lower cost option than reforming. Could this also be used as an alternative gas-to-liquids (GTL) technology?
Example 3 - HTI/Headwaters/Sushuan Coal to Liquids
The DOE has supported pilot plant trials for a 25-30,000 BPD catalytic coal liquefaction technology which may soon get the green light for commercialization in PRC. The technology is based on a nanoscale Fe catalyst that may have important alternative uses.
The above examples show the diversity of new developments that could have important implications. TCGR's study is not limited by them, as we also intend to examine biorenewable feedstocks which are dropping in cost. For example, DOE projects bioethanol will cost $1.07/gal by 2010. Assuming this target is reached, we will economically examine this feedstock potential, as well as biomass catalytic gasification to chemicals.
Example 4 - DuPont's In-Situ Olefin Polymerization
Many companies are developing late transition metal single-site catalyst systems that will allow in-situ alpha-olefin production together with ethylene polymerization in a single reactor. This may help reduce the cost of PE manufacture.
These diverse examples show that many novel process approaches are being pursued everyday. Unfortunately, to-date there has not been a systematic assembly and screening of these opportunities for clients in the polymer and chemical industries. Fortunately, TCGR is now offering to complete this important task for you. Join the Consortium!
Study Benefits:
Clients subscribing to this study will benefit by understanding:
- Where best to make investments in technologies and in the companies developing new approaches.
- How the chemical and polymer industries are changing and responding to both opportunities and threats.
- How academia and governments contribute to the external innovation quotient and what developments should be on the radar screen.
The study will be of interest to a broad set of clients including petrochemical, chemical and polymer companies. Process economics will be used to benchmark against existing processes and to compare them. This report will help many companies rejuvenate their process and product pipelines, as well as their R&D perspectives.
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