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Productivity Advances for Syngas, Olefins and their Derivatives

New Multi-Client Study from TCGR

“Productivity Advances for Syngas, Olefins and their Derivatives”

 There is an ongoing need to improve the energy efficiency and productivity of existing syngas, olefins and derivatives processes because of the improvement in incremental technologies, and catalysts, which are retrofittable into existing operations. These include the extension of turnaround maintenance cycles by reducing coking, more energy efficient refractory wall linings and new catalysts.  When olefin and olefin derivatives processes are examined, there are significant feedstock pretreatment and also product post-treatment separation processes that will allow for feedstock recycle e.g. olefins/paraffins separations into such processes as propylene/propane separation, in polyolefin (PO) and acrylonitrile operations. The opportunity to examine these advantages from a single information source in a systematic way, is a unique opportunity for technology licensors, EPCs, as well as producers and catalyst manufacturers.

TCGR’s proposed assessment entitled “Productivity Advances for Syngas, Olefins and their Derivatives” will systematically review the largest top three (3) maintenance and productivity improvement challenges to improved profitability – for each value chain – and provide pipeline improvement reviews on what the leading-edge solutions being practiced today, including what is around the corner in the next 2-3 years. TCGR has, over the years, provided many syngas, olefins and derivatives benchmarking reports. What is unique about this study is the hands-on operating focus on existing investments, rather than on just new processes and catalysts, i.e. new CAPEX.

In an example, Johnson Matthey retrofitted a steam reformer (for hydrogen production) in the U.S. in February, 2015 with CATACEL™ SSR metal foil reforming catalysts which replaced conventional Ni pellet catalysts in the reformer tubes (see Figure below). Data showed a sustained H2 production rate increased from 71,000 scfh to 85,000 scfh, as well as a fuel savings.

Figure: Fuel Efficiency at Various Operating Ranges

Source: Catacel Corporation, Stackable Structural Reactor (SSR9®) Technology White Paper No. 102

The results captured in TCGR’s study will provide practitioners, developers and prospective partners/evaluators, especially major global chemical (olefins and olefin derivatives) producers, with the commercially proven tools needed to evaluate retrofit options during their next planned turnarounds, via mixing and matching unique solutions in combinations that will add substantially to their bottom lines. Each improvement will be documented and reinforced by field interviews from existing practitioners so that subscribers can verify industrial sources independently for chosen specific routes via an Appendix Directory on company contacts.

Examples of some of the novel technologies to be covered that can offer retrofit processing advantages abound:

  • In-Reactor Chemical (Olefins) Process Advances and Retrofits
    – Thermal Crackers – SCG Chemicals, emisspro®; BASF, QTech; others
    – On-Purpose Propylene (FCC, PDH, etc.) – Sinopec, DCC; Dow, PDH; Axens, MSFCC; Clariant, HGM
    – EO and Derivatives – HS vs. HP optimization
    – PO and Derivatives – Evonik, HPPO; Dow/BASF, HPPO
    – Alpha Olefins – Shell, SHOP; CPChem, Hexene
    – Others (e.g. acrylonitrile) – Arisdyne, CFC; CMS, Optiperm; Imtex, Permylene; etc.
  • Optimization Advances in Syngas Reformers and Derivatives(Important operational issues such as pressure drop, distribution, poisons, by-product control, etc. will be addressed and highlighted in those processes needing the most attention. New interactive packing and materials to address these issues will be introduced).– Reformers – Johnson Matthey, CATACEL, SSR; Haldor Topsoe, ATR; CO2 and Dry Reforming
    – Methanol – Johnson Matthey, MeOH; Carbon Recycling Inc (CRI), MeOH; others
    – Hydrogen – Johnson Matthey, CATACEL, SSR
    – GTL small scale – Velocys; Compact GTL; others
    – Oxo-alcohols – Evonik, ROMEO
    – Acetyls – BP, Acetate
    – Others

TCGR’s report will focus on delivering commercially proven technologies that are available to retrofit into existing operations during your next maintenance turnaround cycle.  The style will be to compose “cameos” of advantaged retrofit technologies that have less than three (3) years payback, then rank them, also providing subscribers with the commercial contacts to pursue their implementation. We expect the chosen improvements will provide an increase in existing throughput, i.e. capacity increase, reduce energy consumption through improved efficiency, and/or reduced GHG emissions or a combination of the above.

This newly proposed study compliments an ongoing portfolio of similarly well received studies that The Catalyst Group Resources has delivered to clients over recent years. This growing experience demonstrates TCGR’s unique capability, resources and expertise to deliver exceptional insight.

As it does in each of its industrially-focused multi-client studies, TCGR will seek input from “charter”
subscribers to help shape the report’s final scope/TofC by delineating areas of particular interest,
including the cameos in Sections III and IV (per the preliminary TofC) in the assessment.

Additional information, including the complete study proposal, the preliminary Table of Contents and the Order Form, is available at
PROP- Productivity Advances Syngas-Olefins-Derivatives (Sept 2017) or by contacting John J. Murphy at +1.215.628.4447 or John.J.Murphy@catalystgrp.com

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The Catalyst Group Resources (TCGR), a member of The Catalyst Group, is dedicated to monitoring and analyzing technical and commercial developments in catalysis as they apply to the global refining, petrochemical, fine/specialty chemical, pharmaceutical, polymer/elastomer and environmental industries.