nanotechnology for oil refinery

Diesel Fuel Hydroskimming Heavy Catalysts (Nebula Type) Production Technology

Light Hydroskimming Catalyst Production Technology

Catalyst type: carrier: aluminum oxide Active component: nano-modified cobalt-molybdenum

2020 203020152010

Number of units

Total capacity, kta

Annual consumption, tons

Annual consumption, $mln

—

—

—

—

—

—

—

—

—

—

—

—

1–2

1 000–2 000

200–300

10–15

Strategic Goals of Russian Producers

Technology

2020 203020152010

Introduction of Russia's own full-cycle catalyst production technologies

Leading edge

30%of Russian

market

40%of Russian

market

50%of Russian

market

65%of Russian

market

Catalyst type: sulfidic

Quality

In inert gas atmosphere

Electric drying with inert gas

purging

Alcoxide-Based Technology


purging






purging

Ru

ss

ia

n

Ma

rk

et

Technology Import

Russian R&D

Nanotechnology Applications in Catalytic Petroleum Refining Processes. Hydroskimming

CATALYST MARKETSScientific and Technical Development

Catalyst Production Technologies Processes and Catalysts (Compounds)

Preparation of Carrier

Preparation of Impregnating

Solution

Impregnation Drying Baking Sulfurization

Catalyst Main Production Stages


Circulatory impregnation

including carrier vacuum treatment


purging

Purging at 300-350°С with a fuel containing sulfur compounds (in a

separate unit)


Blending of two

solutions in the presence of the third component

1

2

3

4

Prod

uctiv

ity (S

pace

Ve

locit

y), h

r.^-1

Capi

tal I

nten

sity

Pow

er C

onsu

mpt

ion

Resi

dual

Sul

fur

Cont

ent,

ppm

Activ

ity

Stre

ngth

Cata

lyst

Ser

vice

Life

be

fore

Reg

ener

atio

n,

year

s

Pric

e, th

$/t

Technical and Economic Characteristics of the

ProcessC a t a l y s t S p e c i f i c a t i o n s




purging

Preparation of nano-structuralized carriers, e.g. on the

basis of titanium dioxide

Synthesis of optimum cobalt-

molybdenum or platinum compounds

directly in the solution

Sulfurization in a separate installation

(with a special sulfur-containing

reactant)


On the refinery siteBaking on the refinery site

Electric drying with air purging

Complete Process Lines



Blending of two

solutions in the presence of the third component

Redeposition Technology

On the refinery site (in a separate

installation)

Purging at 300-350°С with a fuel containing sulfur compounds (in a

separate unit)

Purging at 300-350°С with a fuel containing sulfur compounds (in a separate unit))Development

of Activation Technologies and Equipment

Development of Sulphidation Regimes





Development of Methods to Control Carriers' Honeycomb Structure

Development of Active Component Synthesis Technologies

Blending of two solutions

in the presence of the third component

Development of Oxidative Desulfurization Technologies



Optimization of Drying Conditions

Consumption of valuable feedstock (cobalt and molybdenum content, %) 15–18 15–18 20–24 20–24

10 10 10 10

10 10 6–7 6–7

100 100 100 100Labor intensity (per 1,000 tons of products annually), man

Technical and Economic Characteristics2020 203020152010

Average capital intensity by process stages (per 1,000 tons of products annually), $mln

Power consumption

Capacity output

70–80 70–80 80–90 80–90

Materials consumption


Capital intensity

Power consumption Medium Medium Medium Medium

High High High High

High Medium Medium Medium

Low Low Medium Medium

Yield ratio, %

Yield ratio, % 95–98 95–98 95–98 95–98

Oxidation Technology

1. Carrier preparation. 2. Preparation of impregnating solution. 3. Impregnation. 4. Drying. 5. Baking.

Quality improvement: cleaner fuels

2030 or later

Production stages Advantages Appearance time

Quality improvement: reduction of sulfur and nitrogencontent

2030 or later

Advantages Appearance time

Process:NZSD (<10 ppm)

2015

2020

х2

х2

х2

1,5

1,2

1,2

х1,2

х1,2

х1,2

<10

<10

<10

х2–2,5

х2–2,5

х2–2,5

х1

х1

х1

1,5–2

1,5–2

1,5–2

25–30

25–30

25–30

Catalyst:Carrier: alumina

Active component: nano-modified cobalt-molybdenum

Process:Low (over 50 ppm)

residual sulfur content

х1,5

х1,5

х1

х1

>3,5

2,5–3

2,5

2,5

х1,2

х1,2

х1

х1

50

50

350–50

350

х1,5

х1,2

х1

х1

х1

х1

х1

х1

2

2

3

3

19–25

19–25

19–25

20–22

Process:Very low(over 50 ppm) residual sulfur content (with low space velocityspace velocity)

2010

2015

2020

х1,5

х1,5

х1

х1

2–2,5

1,5–2

1,5–2

1,5–2

х1

х1

х1,2

х1,2

50–10

50–10

50–10

50–10

х1,5

х1,2

х1

х1

х1,2

х1,2

х1

х1

2

2

2

2

19–25

19–25

19–25

20–22

Catalyst:Carrier: alumina

Active component: cobalt-molybdenum

2030

Process:NZSD (<10 ppm)

2010

2015

2020

х1,5

х1,5

х1,5

х1,5

1,5

1,5

1,5

1,5

х1

х1

х1

х1

<10

<10

<10

<10

х2,5–3

х2,5–3

х2,5–3

х2,5–3

х0,8

х0,8

х0,8

х0,8

3

2

2

2

50–60

70–80

70–80

70–80

Catalyst:Nebula type

2030

Process:Very low (50-

10 ppm) residual sulfur

content

2010

2015

2020

х1

х1

х1

х1

3

3

3

3

х1,2

х1,2

х1

х1

50–10

50–10

50–10

50–10

х2,5–3

х2,5–3

х2,5–3

х2,5–3

х0,8

х0,8

х0,8

х0,8

3

3

3

3

50–60

70–80

70–80

70–80

Catalyst:Nebula type

2030

2010

2015

2020

2030

2030

Process: Very low (10-1 ppm) residual sulfur content

Catalyst:Carrier: nano-structuralized titanium dioxide

Active component: cobalt-molybdenum or platinum

Catalyst type: carrier: aluminum oxideActive component: cobalt-molybdenum

2020 203020152010

Number of units

Total capacity, kta



50

70 000

1 500–2 000

100

64

75 000

6 000

250

64–66

75 000

8 000

300

80

90 000

10 000–12 000

400–500

Catalyst type: carrier: aluminum oxideActive component: nickel-molybdenum

2020 203020152010

Number of units

Total capacity, kta



10

10 000

200

6

15

15 000

600

24

20

20 000

1 000

40

20

20 000

1 500

60

Wo

rld

Ma

rke

t Catalyst type: sulfidic

2020 203020152010

Total capacity, kta

Annual consumption, kta


750–800

50–60

2 200

750–800

60–65

2 500–2 600

800–900

70

2 700–2 800

900–1 100

80

3 000–3 500

Lagging behind leaders

Application of purchased foreign

technologies

Catalyst:Carrier: aluminaActive component: cobalt-

molybdenum or nickel-molybdenum

5

6

Development of Bimetallic Compound Synthesis Methods

Blending of two solutions

in the presence of the third component

Synthesis of optimum cobalt-

molybdenum compounds directly

in the solution

Legend:— Low-cost technology

— High-quality production technology

—Normalized assessment of current parameter values. This assessment is used as the basis for future estimations of the same parameters in all analyzed sectors

х1

© State Corporation “Russian Corporation of Nanotechnologies”, 2010

Ru

ss

ia

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Ma

rk

et

Catalyst type:Bead aluminosilicate zeolite-containing catalyst

2020 203020152010

Number of units

Total capacity, kta



11

5 850

7 200

18

7

4 000

4 900

15

3

1 800

2 200

8

—

—

—

—

2020 203020152010

Number of units

Total capacity, kta



16

24 180

10 500

42

19

30 700

14 000

63

22

37 000

16 000

80

25

43 000

19 000

115

2020 203020152010

Number of units .

Total capacity, kta



—

—

—

—

—

—

—

—

2

4 000

1 800

11

5

10 000

4 500

32

Blending of zeolite and

aluminosilicate matrix

Electric heating In liquid phase

Gel-based zeolite

synthesis method

Substitution of sodium ion with

ammonium ion or ions

or rare-earth elements

1. Preparation of sodium aluminate and ammonium

nitrate solutions, separation of rare-

earth elements.2. Synthesis of

aluminum hydroxide3. Clay drying block

In fire furnace

In fire furnace

Technology Import

Russian R&D

Nanotechnology Applications in Catalytic Petroleum Refining Processes. Catalytic Cracking



World Market

Technology

2020 203020152010


Leading edge

80%of Russian

market + 20% of CIS market

80%of Russian

market

60%of Russian

market

20%of Russian

market

Marketing

Quality

х1 х1 х1 —

х1 х1 х1 —

х1 х1 х0,9 —

Labor consumption


Capital Intensity

Power Consumption

Bead Cata lyst Product ion Technology

Baking equipment and filters

Preparation of zeolite (active component)

Preparation of amorphous

aluminosilicate matrix (carrier)

Zeolite modification with rare-earth

elements through ion exchange

Thermocouple stabilization

Zeolite baking Injection of modified zeolite into amorphous aluminosilicate

matrix

Baking and thermocouple stabilization

Forming and drying




Electric heatingIn liquid phase

Gel-based zeolite synthesis

method


ammonium ion or ions or rare-earth

elements



earth elements.2. Synthesis of aluminum

hydroxide3. Clay drying

block

In fire furnace1



Electric heatingIn gas phase

Gel-based zeolite synthesis

method


ammonium ion or ions or rare-earth

elements



earth elements.2. Synthesis of

aluminum hydroxide3. Clay drying block

In fire furnace2

In fire furnace

In fire furnace

Preparation of zeolite (active component)

Preparation of amorphous

aluminosilicate matrix (carrier)

Feedstock preparation (cleaning) technology

will be developed by

2020 resulting in the growth of catalyst selectivity

and activity

Zeolite modification with rare-earth

elements through ion exchange

Thermocouple stabilization

Zeolite baking Injection of modified zeolite into amorphous aluminosilicate

matrix

Baking and thermocouple stabilization

Microsphere formation and spray drying


х0,7 х0,6 х0,65 х0,5

х2 х2,2 х2,4 х2,5

х1,8 х1,7 х1,6 х1,5

Labor consumption


Capital Intensity

Power Consumption

Microsphero ida l Cata lyst Product ion Technology

Yiel

d of

des

ired

prod

uct

(gas

olin

e cu

t) pe

r ton

of

feed

stoc

k (a

nnua

l ope

ratio

n tim

e: 8

,000

hr),

%

Capi

tal i

nten

sity

(at 6

00

kta

thro

ughp

ut)

Man

ual l

abor

sha

re

Pow

er c

onsu

mpt

ion,

kW

hr/to

n of

feed

stoc

k

Activ

ity (c

rack

ing

conv

ersi

on ra

tio),

%

Mic

ro-a

ctiv

ity, %

Wea

ring

qual

ity, %

Pric

e, th

$/t

Technical and Economic Characteristics of the Process

C a t a l y s t S p e c i f i c a t i o n s

х1,5

х1,5

х1,5

х1,5

56

54

52

50

х0,5

х0,5

х0,5

х0,5

720

750

750

780

78

76

73

70

71

65

58

52

97

93

90

87

6

4

3

2

2015

2020

2030

Catalyst:Microspheric (dust-like with average particle diameter 10-70 mkm)

aluminosilicate zeolite-containing catalyst with

optimized content of

Process:«Mili-second» cracker

2010

Catalysts2020 203020152010

Total capacity, mta



765

300

1 200

780

320

1 450

790

350

1 750

800

360

2 150 W

orl

d M

ark

et

х2,5

х2,5

х2,5

х2,5

60

58

56–58

54

х0,5

х0,6

х0,65

х0,7

750

780

800

820

78

76

73

70

71

65

58

52

97

93

90

87

6

4

3

22010

2015

2020

2030


aluminosilicate zeolite-

Process:Double regeneration

cracker for heavy feedstock

х2

х2

х2

х2

60

58

56–58

54

х0,5

х0,6

х0,65

х0,7

720

750

750

780

78

76

73

70

71

65

58

52

97

93

90

87

6

4

3

22010

2015

2020

2030


aluminosilicate zeolite-containing catalyst

Process:Lift-reactor cracker

Process:Moving-bed cracker with

fluidized catalyst bed

х2

х2

х2

53–54

48–50

48–50

х0,8

х0,85

х0,85

780

780

800

75

70

70

55

54

50

92

88

86

4

3

22010

2015

2020

Catalyst:Microspheric (average particle

diameter 10-150 mkm) aluminosilicate zeolite-

containing catalyst

Process:Moving-bed cracker

х1

х1

х1

50–52

50

43–46

х1

х1

х1

600

600

650

68

65

63

50

48

46

88

86

84

2

1,8

1,52010

2015

2020

Catalyst:Bead aluminosilicate

zeolite-containing catalyst

Matrix modification

Synthesis of various types of zeolite, including those with wide mesopores, for catalytic cracking of heavy crude oil and for the «mili-second» process

Development of technologies for baking in controlled gas environments

Processing regimes

Optimization of baking conditions

Blending equipment

Zeolite synthesis equipment

Spray drying equipment

Baking equipment including drum furnaces

Ash-based zeolite

synthesis method




hydroxide3. Clay drying block

4Blending of zeolite and


In fire furnace

Electric heating

Substitution of sodium ion with ammonium ion or ions or rare-earth elements

Pulp filtration (centrifugal separation) equipment



Ash-based zeolite

synthesis method

In fire furnace




hydroxide3. Clay drying

block

In fire furnace

In gas phase

Substitution of sodium ion with ammonium ion or ions or rare-earth elements

Electric heating

Development of compound homogenization technologies

In fire furnace

In gas phase

— Normalized assessment of current parameter values. This assessment is used as the basis for future estimations of the same parameters in all analyzed sectors

Legend:

— Low-cost technology


х1

Development of catalysts resistant to metal poisoning (vanadium, nickel) to process fuel oil

3

Feedstock preparation (cleaning)

5

Catalyst type:Microspheric (dust-like with average

particle diameter 10-150 mkm) aluminosilicate zeolite-containing catalyst

Catalyst type:Microspheric (dust-like with average particle diameter 10-70 mkm) aluminosilicate zeolite-containing catalyst

with optimized content of rare-earth elements


W o r l d M a r k e t

2020 203020152010



3 000

450

3 500

550

4 000

625

4 500–5 000

700–750

Technology Import

Russian R&D

Nanotechnology Applications in Catalytic Petroleum Refining Processes. Light Gasoline Cut IsomerizationRefining Processes. Light Gasoline Cut Isomerization

CATALYST MARKETSScientific and Technical Development Catalyst Production Technologies Processes and Catalysts (Compounds)


Technology

2020 203020152010


Leading edgeSlightly lagging behind

the world leaders

30%of Russian

market

40%of Russian

market

50%of Russian

market

50%of Russian

market + 20% of CIS market

Marketing

Quality

Prod

uctiv

ity, t

ons

of

feed

stoc

k / t

ons

of c

atal

yst

per h

our

Capi

tal I

nten

sity

Labo

r con

sum

ptio

n

Pow

er c

onsu

mpt

ion

% o

f byp

rodu

cts

Stre

ngth

, kg/

cm

Sele

ctan

ce, %

wgh

t

Pric

e, th

$/t


ProcessCatalyst

Specifications

Preparation of feedstock


Preparation of solution


Autoclave crystallization


Washing, filtration, wastewater disposal


Ion exchange, modification


Application of precious metal

Granulation with binding substance


Drying, baking

Drying, baking

Medium Temperature Catalyst Main Production Stages

High Temperature Catalyst Main Production Stages

R u s s i a n M a r k e t

2020 203020152010

Number of units



14

140–150

15–22

18

200–300

30–45

23

350–400

52–60

30

550

85

х1

х1

х1

х1

х1

х1

х1

х1

х1

х1

х1

х1

2–5

2–5

2–5

5–8

60–80

60–80

50–70

50–70

95–98

95–98

95–98

92–95

80

75

75

702010

2015

2020

2030

Catalyst:Chlorinated alumina;

zirconium oxide promoted with

sulfate, molybdate, or tungstate ions

Process:Low-temperature isomerization

5

5

4

4

х2,75

х2,75

х2,75

х2,75

х1,3

х1,3

х1,3

х1,3

х2

х2

х2

х2

10–15

10–15

10–15

10–15

60–80

60–80

50–70

50–70

85–90

85–90

85–90

85–90

155

150

150

1302010

2015

2020

2030

Catalyst:Based on mordenite-

type zeolites (containing sodium in a volume of 2-3 ppm) modified with 0.4-0.5% whgt. platinum

Process:Medium-temperature

isomerization

0,5–1,5

0,5–1,5

0,5–1,5

0,5–1,5

х3

х3

х3

х3

х1,3

х1,3

х1,3

х1,3

х3

х3

х3

х3

15–25

15–25

15–25

15–25

60–80

60–80

50–70

50–70

75–85

75–85

75–85

75–85

155

150

150

1302010

2015

2020

2030

Catalyst:Based on fluorinated

alumina or ZSM-5 type medium-porous zeolites

Process:High-temperature isomerization

0,5–1,5

0,5–1,5

0,5–1,5

0,5–1,5

Belt-type baking furnaces for continuous baking at temperatures up to 600°С

Development of methods for simultaneous application of precious metals and sulfate

Improvements in wet formation of bead catalyst in oil column

Development of technologies for catalyst granulation without binding agents

х2 х2 х1,8 х1,8х0,5 х0,5 х0,6 х0,6

х2,5 х2,5 х2,5 х2,5х2,5 х2,5 х2,5 х2,5

> 85 % > 90 % > 95 % > 95 %

Labor consumption

Technical and Economic Characteristics 2020 203020152010

Capital Intensity

Power consumption

Technology for Preparation of High-Temperature Catalysts on the Basis of ZSM-5 Type Medium-Porous Zeolites

Yield ratio, %

Productivity

х1 х0,8 х0,7 х0,7х1 х1,2 х1,5 х1,5

х1 х0,7 х0,6 х0,6х1 х0,8 х0,7 х0,6

> 90 % > 95 % > 95 % > 95 %

Labor consumption


Capital Intensity

Power consumption

Improvement of continuous zeolite synthesis technology

Yield ratio, %

Productivity

х2 х2 х2 х2х0,3 х0,3 х0,3 х0,3

х3 х3 х3 х3х3 х3 х3 х3

> 85 % > 90 % > 95 % > 95 %

Labor consumption


Capital Intensity

Power consumption

Technology for Preparation of Medium-Temperature Catalysts on the Basis of Mordenite-Type Zeolites (Containing Sodium in a Volume of 2-3 ppm)

Yield ratio, %

Productivity

Mechanical grinding in ball crushers (preparation of water – process condensate,

electrical desalination



Filtration in continuous-type scroll centrifuges / intermittent filtration in regular

centrifuges


centrifuges


centrifuges


centrifuges

Filtration in nutch filters or press filters

Mechanical grinding in planetary crushers (preparation of water – distillation, ion-

exchange resins), possible ultrasonic crushing of inoculant







Multiple intermittent ion exchange in agitators with heating at atmospheric

pressure

Single-time intermittent ion exchange in autoclaves at high pressure and

temperature


temperature


temperature

Intermittent ion exchange in agitators with heating at atmospheric pressure

Intermittent ion exchange in autoclaves at high pressure and temperature



Granulation in screw extruders integrated with z-shape blade

mixers


mixers

Intermittent in muffle furnace / intermittent or continuous in shaft

furnaces


furnaces


furnaces

Continuous in regular or vacuum belt furnaces


furnaces


furnaces

Granulation with binding substance in screw extruders integrated with z-shape

blade mixers


blade mixers


blade mixers

Wet formation of bead catalyst in oil column





Solution of salts in water, mechanical blending








Intermittent

Intermittent

Continuous

Filtration in nutch filters or press filters

Intermittent impregnation (possibly combined with ion

exchange)


exchange)


Continuous impregnation (by analogy with preparation of

reforming catalysts)



Intermittent

Intermittent

Continuous

Preparation of active componentPreparation of solution Application of precious metal

Catalyst granule thermal treatment

Low-Temperature Catalyst Main Production Stages

Solution of salts in water, mechanical blending (agitation units)



Redeposition with agitation and heating combined with modification by means of sulfate ions

Redeposition with agitation and heating combined with modification by means of sulfate ions and ultrasonic dispergation

Redeposition with agitation and heating combined with modification by means of sulfate ions and ultrasonic dispergation

Intermittent impregnation / intermittent impregnation combined with ion exchange

Continuous impregnation (by analogy with preparation of reforming catalysts)

Continuous impregnation (by analogy with preparation of reforming catalysts)

Granulation with binding substance in screw extruders integrated with z-shape blade mixers


1

4

5

8

9

2

3

Intermittent in muffle furnace / intermittent or continuous in shaft furnaces



Continuous in regular or vacuum belt furnacesContinuous

Continuous

Blending of active component with alumina and subsequent granulation

Granulation with binding substance in screw extruders integrated with z-shape blade mixers

Agitating autoclaves with a heating range of up to 200°С for zeolite synthesis

Equipment for wet formation of bead catalyst in oil column




centrifuges


centrifuges

Scroll centrifuges for continuous filtration and washing of wet synthesized products

Improvement of continuous zeolite synthesis technology

11

10

7

6

— Normalized assessment of current parameter values. This assessment is used as the basis for future estimations of the same parameters in all analyzed sectors.

Legend:


— Low-cost technology х1


Reduction in hydrogen

stream

Non-residuum

impregnationContactless

Uniform refluxing With poly-

sulfides

Chlorination with the use of CCl4 or C2H4Cl2

Evaporation by means of microwaves

Low-temperature heating in furnace

By the ammonia-

hydrocarbon formation method

Technology Import

Russian R&D

Nanotechnology Applications in Catalytic Petroleum Refining Processes. Catalytic Reforming



Technology

2020 203020152010


Application of purchased

foreign technologies

Leading edge

80%of Russian

market

60–70%share of Russian

market

50%of Russian

market

20%of Russian

market

Marketing

Quality

х1 х1 х1 х1

х1 х1 х1,1 х1,15

х1 х1 х1 х1

6–8 6–8 6–8 6–8

Labor consumption


Capital Intensity

Power consumption

Technology for Preparation of Bead «Platinum of Alumina» Catalysts by the Ammonia-Hydrocarbon Formation Method

Rejection rate, %

х1 х1 х1 х1

х1 х1 х1,1 х1,1

х1 х1 х1 х1

8–10 8–10 8–10 8–10

Labor consumption


Capital Intensity

Power consumption

Technology for Application of Platinum on Alumina (Extrudate Preparation)

% брака

х1,1 х1,1 х1,02 х1

х1,1 х1,15 х1,2 х1,2

х1,2 х1,2 х1,3 х1,3

6–8 6–8 6–8 6–8

Labor consumption


Capital Intensity

Power consumption

Technology for Preparation of Zeolite Platinum Containing Catalysts

% брака

Octa

ne N

umbe

r

Gaso

line

Yiel

d, %

wgh

t

ТLab

or c

onsu

mpt

ion

Spac

e Ve

loci

ty),

hr.^

-1

Capi

tal I

nten

sity

Pow

er C

onsu

mpt

ion,

kW

/t

Mic

ro-a

ctiv

ity, %

Wea

ring

qual

ity, %

Pric

e, th

$/t


Catalyst Specifications

Ru

ss

ia

n

Ma

rk

et

Catalyst type:Zeolitic, platinum containing

2020 203020152010

Number of units

Total capacity, kta



3

3 000

50

1

5

5 000

85

2,15

8

8 000

135

3,6

12

12 000

200

6,4

Catalyst type: Platinum on alumina and zeolitic platinum containing

2020 203020152010

Total capacity, mta



525

8 750

175

560

9 300

230

600

10 000

270

675

11 250

360 Wo

rld

Ma

rke

t

Moistening by water vapor

Preparation of carrier

(formation)

Water evaporation

Drying Baking Reduction in hydrogen

stream

SulfurizationChlorination (activation)

Main Stages of Technology for Application of Platinum on Alumina (Extrudate Preparation)


stream

Non-residuum

impregnation ContactUniform refluxing3

With elementary

sulfur

Chlorination with

gaseous HCl

Heating in furnace


Extrusion


Bead Formation Water evaporation


stream


Main Stages of Technology for Preparation of Bead «Platinum of Alumina» Catalysts by the Ammonia-Hydrocarbon Formation Method


stream

Non-residuum

impregnationContact

Uniform refluxing With poly-

sulfides

Chlorination with

gaseous HCl

Heating in furnace


Impregnation of carrier with platinum and

rhenium solutions


Preparation of carrier

(formation)

Water evaporation


stream


Main Stages of Technology for Preparation of Zeolite Platinum Containing Catalysts


streamКонтактная4 With poly-

sulfidesChlorination with gaseous

HCl


Extrusion


streamContactless5 With poly-

sulfides

Chlorination with the use of CCl4 or C2H4Cl2

Evaporation by means of microwaves


Extrusion

х0,75

х0,8

х0,85

х0,85

103

102

101

100

3

2,4

2,2

2

х2

х1,9

х1,8

х1,8

160

170

175

180

60

65

68

70

300–350

280

270

250

80–100

80

70

40–60

Catalyst:Platinum on

alumina

Process:Moving catalyst bed

92

90

89

87–89

2020

2015

2010

2030

х0,75

х0,8

х0,85

х0,85

105

104

103

102

3,2

2,8

2,4

2,2

х2

х1,9

х1,8

х1,8

160

170

175

180

59

65

66

67

300–350

300

290

280

80–100

80

70

40–60

Catalyst:Zeolitic, platinum

containing

Process:Moving catalyst bed

94

92

91

90

2020

2015

2010

2030

Catalyst type:Platinum on alumina

2020 203020152010

Number of units

Total capacity, kta



58

20

330

6,6

60

22–25

420

9,4

60

22–25

420

10,5

62

30

500

15

х0,8

х0,9

х1

х1

100

98

96

95

2,5

2

1,9

1,7

х1

х1

х1

х1

120

125

130

130–140

59

59

60

62

220

190

170

120–150

80–100

80

70

40–60


containing

Process:Fixed catalyst bed with intermediate heating between the reaction zones

90

89

88

85–87

х0,8

х0,9

х1

х1

98

97

96

93–95

2

1,7

1,5

1,3–1,5

х1

х1

х1

х1

120

125

130

130–140

60

61

63

64

220

190

170

120–150

80–100

80

70

40–602010

2015

2020

2030


containing

Process:Fixed catalyst bed with intermediate heating between the reaction zones

90

88

86

82–852

Development of catalysts ensuring high octane numbers at smooth processing regimes

Development of hydrogen yielding catalysts

Equipment for reduction in hydrogen stream

Drying equipment

— Normalized assessment of current parameter values. This assessment is used as the basis for future estimations of the same parameters in all analyzed sectors

Legend:

—Low-cost technology


х1

2020

2015

2010

2030

1

By the ammonia-

hydrocarbon formation method

Development of catalysts with improved mechanical strength and high catalytic activity for moving-bed installations

Carrier production equipment

Uniform refluxing

Uniform refluxing

Heating in furnace

Non-residuum

impregnation

Non-residuum

impregnation

Impregnation of carriet with platinum and

rhenium solutions

Impregnation of carriet with platinum and

rhenium solutions


Catalyst type: On the basis of amorphous and crystalline

alumosilicates containing sulfide nano-particles of NiWS phase

2020 203020152010

Number of units

Total capacity, kta



2

5

300

10,5

4

10,4

600

21

5

12,4

800

28

7

17,4

1 000

35

Technology Import

Russian R&D

Nanotechnology Applications in Catalytic Petroleum Refining Processes.Hydrocracking

CATALYST MARKETSScientific and Technical

Development



Technology

2020 203020152010

Introduction of Russia's own

full-cycle catalyst production

technologies

Application of purchased

foreign technologies

Slightly lagging behind the world leaders

Not produced in Russia


—

—

—

—

50%of Russian

market

65%of Russian

market

Marketing

Quality

Technica l and Economic Character is t ics o f the

ProcessEconomicCharacter is t ics o f the ProcessProcess

Prod

uctiv

ity (a

mou

nt o

f fe

edst

ock

proc

esse

d,

tons

)

Pow

er c

onsu

mpt

ion

Activ

ity

Sele

ctan

ce

Wea

ring

qual

ity, %

Pric

e, th

$/t


Stre

ngth

Wo

rld

Ma

rk

et



Preparation of zeolite

component (or alumosilicate)

Preparation of Zeolite Compound


Solution


Solution

Impregnation

Impregnation

Drying

Drying

Baking.

Baking

Sulfurization (transition into sulphide phase)

Reduction (treatment to bring platinum

into metallic state

Main Catalyst Production Stages

Main Catalyst Production Stages

—

—

Single-stage

Single-stage

With polysulfide compounds

In hydrogen stream

Extrusion, drying and

baking


baking

Preparation of common

tungsten-nickel solution

Preparation of platinum containing solution

1

1

Productivity

Productivity

х1 х1 х1 х1

х1 х1 х1 х1

х1 х1 х1 х1

х1 х1 х1 х1

х1 х1 х0,98 х0,96

х1 х1 х0,98 х0,96

х1 х0,98 х0,96 х0,94

х1 х0,98 х0,96 х0,94

Labor consumption

Labor consumption

Technical and Economic Characteristics


2020

2020

2030

2030

2015

2015

2010

2010

Capital Intensity

Capital Intensity

Power consumption

Power consumption

Technology for Preparation of Catalysts on the Basis of Amorphous or Crystalline Alumosilicates Containing Sulfide Nano-Particles of NiWS Phase

Technology for Preparation of Catalysts on the Basis of Crystalline Alumosilicate (Zeolites) Containing Platinum Nano-Particles

Yield ratio, %

Rejection rate, %

97–98 97–98 98 99

97–98 97–98 98 99

Hydrothermal synthesis


Electrical drying in air or nitrogen

stream

Electrical drying in air or nitrogen

stream

2 Hydrothermal synthesis


baking—

In fume gases

Preparation of platinum containing solution

With feedstock containing dimethyl disulfide

Single-stage

2

With feedstock containing dimethyl disulfide



baking

Preparation of common

tungsten-nickel solution

Single-stage —In fume gases

Equipment for catalyst impregnation (fixation of bimetallic compounds on carrier surface)

2010

х1

х1

х1

х1

х1,06

х1,04

х1,03

х1

х0,97

х0,97

х0,97

х1

5

5

4

4

9

8

7

7

9

8

7

6

4

3

2

2

17–22

17–22

14–18

14–18

2030

2020

2015

Catalyst:On the basis of amorphous

alumosilicates containing sulfide nano-particles of NiWS phase

Process:Single-stage

hydrocracking

2010

х1

х1

х1

х1

х1,6

х1,57

х1,55

х1,5

х1,2

х1,3

х1,4

х1,5

10

9

8

7

9

8

7

7

9

8

7

6

10

8

7

6

20–24

20–24

16–20

16–20

2020

2015

Catalyst:On the basis of crystalline alumosilicates (zeolites)

containing platinum nano-particles

Process:Two-stage

hydrocracking

2030

Ru

ss

ian

Ma

rk

et

Catalyst type:Alumosilicate-based

2020 203020152010

Total capacity, kta



22–26

25–30

875–1 050

26–30

30–35

1 050–1 220

30–35

35–40

1 220–1 400

39–44

45–50

1 575–1 750

2010

х1,4

х1,4

х1,4

х1,4

х1,06

х1,04

х1,03

х1

х0,97

х0,97

х0,97

х1

9

8

7

6

9

8

7

7

9

8

7

6

9

7

5

4

20–24

20–24

16–20

16–20

2030

2020

2015

Catalyst:On the basis of crystalline alumosilicates (zeolites)

containing sulfide nano-particles of NiWS phase

Process:Single-stage

hydrocracking

х1 — Normalized assessment of current parameter values. This assessment is used as the basis for future estimations of the same parameters in all analyzed sectors.

Legend:


—High-quality production technology

Score indicated as per a ten-point scale

Development of technologies to form catalysts in solutions of bimetallic compounds with particle sizes of about 1 nm

C

apita

l Int

ensi

ty


Nanotechnology Applications in Catalytic Petroleum Refining Processes. Processing of Associated Petroleum Gas – Part I



Technology

2020 203020152010


Leading edge


—

—

5%of Russian

market

10%of Russian

market

20%of Russian

market

Marketing

Quality

Preparation of feedstock Preparation of solution Кристаллизация в автоклавах


Ion exchange, modification Application of precious metal


Drying, baking

Main Stages of Technology for Preparation of Zeolite Catalyst to Synthesize Gasoline from Dimethyl Ether

х1 х1 х1 х1х1 х1 х1 х1

х1 х0,9 х0,8 х0,8х1 х0,9 х0,8 х0,860 70 80 95

Labor consumption


Capital Intensity

Power consumption

Technology for Preparation of Cobalt or Iron Nano-Particles Used as Catalysts in Fischer-Tropsch Process

Yield ratio, %

Valuable feedstock consumption

х1 х1 х1 х1х1 х0,8 х0,7 х0,7

х1 х1 х0,8 х0,8х1 х1 х0,8 х0,870 70 80 95

Labor consumption


Capital Intensity

Power consumption

Technology for Production of Catalysts of the Basis of ZSM-5 Type Zeolites to Synthesize Gasoline from Dimethyl Ether

Yield ratio, %







centrifuges





Многократный периодический ионный обмен в аппаратах с перемешиванием и подогревом при атмосферном давлении

Однократный периодический ионный обмен в автоклавах под давлением и при повышенных температурах


mixers


mixers


furnaces


furnaces


furnaces





Crystallization

Intermittent

Continuous



exchange)


exchange)






Preparation of micro-emulsionsPreparation of salt solutions Catalyst activation

Main Stages of Technology for Preparation of Cobalt or Iron Nano-Particles Used as Catalysts in Fischer-Tropsch Process

Preparation of invert micro-emulsion Evaporation of water from micro-emulsions Thermal treatment in hydrogen stream

Thermal treatment in carbon oxide stream

Thermal treatment in hydrogen stream

Thermal treatment in carbon oxide stream

Preparation of water solutions1

2

3

4

Preparation of suspensions


7

8

10

9



— Normalized assessment of current parameter values. This assessment is used as the basis for future estimations of the same parameters in all analyzed sectors.

х1

х0,5 х0,5 х0,4 х0,4х2 х2 х4 х6

90 90 95 95

Трудоемкость


Capital Intensity

Энергопотребление

Technology for Preparation of Membrane-Catalytic Catalyst for Fischer-Tropsch Process (Compared to ZSM-5 for Aromatization)

Выход годных, %


х0,5 х0,5 х0,4 х0,3х0,3 х0,3 х0,2 х0,2

Preparation of powdersCo-deposition Membrane baking and catalyst activation

Passivation of membrane-catalytic element

Main Stages of Technology for Preparation of Membrane-Catalytic Catalysts for Fischer-Tropsch Process

Co-deposition of common hydroxocarbonate (HOC) of Co and Al and promoting components

Blending and compaction of complex-shape membrane defined by reactor geometry

Membrane baking and catalyst activization Passivation of membrane-catalytic elementPreparation of powders of Со-Al HOC, metallic copper and malachite with specified fraction composition and

moisture content5

Blending and compaction of membrane

Passivation of membrane-catalytic element

ПPreparation of powders of Со-Al HOC, metallic aluminum and malachite with specified fraction

composition and moisture content

Co-deposition of common hydroxocarbonate of Co and Al and promoting components

Blending and compaction of complex-shape membrane defined by reactor geometry

Membrane baking and catalyst activization6

Prod

uctiv

ity, t

ons

of fe

edst

ock

/ ton

s of

ca

taly

st p

er h

our

Capi

tal i

nten

sity

(com

pare

d to

the

curr

ent v

alue

for F

isch

er-T

rops

ch

(ORY

X =

1.5

mm

t of p

rodu

cts

per y

ear,

CAPE

X =

$100

0 pe

r ton

per

yea

r)

ТPow

er c

onsu

mpt

ion

(com

pare

d to

the

cur

rent

val

ue o

f Fis

cher

-Tro

psch

pro

cess

)

Pow

er c

onsu

mpt

ion

(com

pare

d to

the

curr

ent v

alue

of F

isch

er-

Trop

sch

proc

ess)

С5+

sele

ctan

ce, %

Met

hane

sel

ecta

nce,

%

Stre

ngth

, kg/

cm2

Pric

e, th

$/t


ProcessCatalyst

Specifications

Prod

uctiv

ity, k

g of

pro

duct

(gas

olin

e

Capi

tal i

nten

sity

(com

pare

d to

the

curr

ent v

alue

for F

isch

er-T

rops

ch

(ORY

X =

1.5

mm

t of p

rodu

cts

per y

ear,

CAPE

X =

$100

0 pe

r ton

per

yea

r)

Pow

er c

onsu

mpt

ion,

Whr

/ton

of

feed

stoc

k

Serv

ice

cycl

e, m

onth

s

Tota

l ser

vice

life

, yea

rs

Stre

ngth

, kg/

mm

2

Pric

e, th

$/t


ProcessCatalyst

Specifications

х0,8

х0,9

х1

х1

х0,9

х0,9

х1

х1

х0,8

х0,9

х1

х1

90

87

85

80

<5

8

8

10

—

—

—

—

25

25

20

202010

Catalyst:Cobalt or iron nano-

particles

Process:Fischer-Tropsch

0,7

0,5

0,4

0,3

2030

2020

2015

х0,8

х0,8

х0,9

х1

170

170

185

185

>2

>2

>2

>2

1,4

1,4

1,4

1,2

>3

>3

>3

>3

120

115

110

1002010

Catalyst:On the basis of ZSM-5 type zeolites to

synthesize gasoline from dimethyl ether

Process:In single-loop two-

reactor module

0,8

0,8

0,7

0,7

2030

2020

2015

х0,7

х0,9

—

—

х1

х1

—

—

х1

х1

—

—

85

80

—

—

8

15

—

—

1,5

1

—

—

40

50

—

— 2010

Catalyst:Membrane-catalytic

Process:Fischer-Tropsch

1

0,7

—

—

2030

2020

2015

—

—

—

—

—

—

—

—

>2

>2

>2

>2

2,2

2,2

2,2

2,2

>3

>3

>3

>3

30

25

25

202010

Catalyst:Alumina-based metal-oxide for synthesis of dimethyl ether from associated

petroleum gas

Process:In single-loop two-

reactor module

—

—

—

—

2030

2020

2015

Catalyst type:Membrane-catalytic

2020 203020152010

Total capacity, mta



—

—

—

—

—

—

20

2

0,02

100–200

6–10

0,1–0,15

Catalyst type:Cobalt or iron nano-particles

2020 203020152010

Total capacity, mta



2 000

1 000

20

3 000

1 500

30

3 000

1 500

30

4 000

1 500

40

Wo

rl

d

Ma

rk

et

Catalyst type Cobalt or iron nano-particles

2020 203020152010

Number of units

Total capacity, kta



—

—

—

—

1

20

4

0,13

5

100

20

0,5

20

1 000

200

5

Catalyst type: Membrane-catalytic

2020 203020152010

Number of units

Total capacity, kta



—

—

—

—

—

—

—

—

1

10

1

0,02

2–3

50–60

3–5

0,06–0,1

Catalyst type:Metal-oxide

2020 203020152010



—

—

72

1,5

360

7,5

1 440

30

Catalyst type:On the basis of ZSM-5 type zeolites

2020 203020152010

Number of units .

Total capacity, kta



Annual consumption,

—

—

—

—

—

1

100

60

36

3,6

5

500

300

180

18

20

2 000

1 200

720

72

Ru

ss

ia

n

Ma

rk

et

Technology Import

Dimethyl ether production

Fischer-Tropsch process

Fischer-Tropsch process

Dimethyl ether production

Russian R&D

Development of stable micro-emulsions

Development of efficient methods to separate nano-sized catalysts from synthesis products

Belt-type baking furnaces for continuous baking at temperatures up to 600°С

Agitating autoclaves for decomposition in organic media at high (up to 350°С) temperature

Improvement of methods to promote nano-size catalysts

Scroll centrifuges for continuous filtration

Electrical and magnetic filters

Improvement of technologies for continuous synthesis of ZSM–5 type medium-porous zeolites

Development of efficient methods to regenerate and recirculate nano-sized catalystsббrecirculate nano-sized catalystscirculate nano-sized catalysts

Development of more efficient methods to modify zeolites to improve their selectance

Evaporation of water from micro-emulsions



Preparation of invert micro-emulsion



Blending equipment

Continuous


centrifuges


centrifuges



Equipment for wet formation of bead catalysts

Autoclaves for continuous zeolite crystallization

Development of technologies for catalyst granulation without binding agents


temperature


temperature

Improvement of technologies for wet formation of bead catalyst in oil column

Legend:

Preparation of water solutions





Technology Import

Production of carbonnano-fibers

Associated petroleum gas aromatization

Associated petroleum gas aromatization

Production of carbon nano-fibers

Russian R&D

Nanotechnology Applications in Catalytic Petroleum Refining Processes. Processing of Associated Petroleum Gas – Part II



Technology

2020 203020152010


Leading edge—

—

20%of Russian

market

10%of Russian

market

5%of Russian

market


Marketing

Quality

Medium Medium Medium Medium

High High High High



Labor consumption


Capital Intensity

Productivity

Power consumption

Technology for Preparat ion of Cobal t or I ron Nano-Par t ic les Used as Cata lysts in F isher-Tropsch Process



Preparation of composite material


Loading of composite material into activating grinder

Washing, filtration,

wastewater disposal


Mechanochemical activation


Drying, baking

Thermal treatment

Application of dehydration component

Forming

Main Stages of Technology for Preparation of Catalysts for Aromatization of Associated Petroleum Gas on the Basis of ZSM-5 Type Zeolites

Main Stages of Technology for Preparation of Oxide Catalysts for Pyrolysis of Hydrocarbons into Carbon Nano-Fibers

Ru

ss

ia

n

Ma

rk

et

Catalyst type: Cobalt or iron nano-particles

2020 203020152010

Number of units

Total capacity, kta



—

—

—

—

2

100

20

0,65

20

1 000

200

6,5

50

2 500

500

16,5

Catalyst type: On the basis of ZSM-5 type zeolites

2020 203020152010

Number of units .

Total capacity, kta



—

—

—

—

2

0,4

12

0,02

8

2

50

0,07

100

50

1 000

1

Catalyst type: Membrane-catalytic

2020 203020152010

Number of units

Total capacity, kta



—

—

—

—

2

0,4

12

0,02

8

2

50

0,07

100

50

1 000

1

Catalyst type: Iron or nickel nano-dispersed

2020 203020152010

Total capacity, mta



0,2

70

0,5

1,5

600

4

8

3 000

20

40

10 000

80

Catalyst type: Powdered micron systems composed of nickel and iron nano-particles

2020 203020152010

Total capacity, mta

Annual consumption, ktaт


0,8

0,4

2

8

3

20

40

12

100

200

50

500

Catalyst type: On the basis of medium-porous ZSM-5 type zeolites

2020 203020152010

Тotal capacity, mta



—

—

—

200

60

2,1

2 500

750

26

12 500

3 800

110

Wo

rl

d

Ma

rk

et

х0,1

х0,1

х0,1

х0,1

0,5 – 1,5

0,5 – 1,5

0,5 – 1,5

0,5 – 1,5

0,2 – 0,3

0,2 – 0,3

0,2 – 0,3

0,2 – 0,3

0,3 – 0,4

0,3 – 0,4

0,3 – 0,4

0,3 – 0,4

32,7

32,7

32,7

32,7

70 – 72

70 – 72

40 – 45

40 – 452010

2015

2020

2030

Catalyst:On the basis

of ZSM-5 type zeolites

Process:Aromatization of associated petroleum

gas in adiabatic reactors with fixed catalyst bed

Development of more efficient methods to modify zeolites to improve their selectance

Improvement of technologies for wet formation of bead catalyst in oil column

Thermal treatment equipment

Spray dryers

Granular materials classification equipment

Autoclaves for continuous zeolite crystallization

Improvement of technology for continuous synthesis of ZSM-5 type zeolites

1

Mechanical grinding in ball crushers (preparation

of water – process condensate, electrical

desalination

Solution of salts in water, mechanical

blendingIntermitten

Filtration in nutch filters or press

filters

Intermittent ion exchange in agitators

with heating at atmospheric pressure


mixers

Intermittent impregnation

(possibly combined with ion exchange)


2



desalination


blendingIntermitten

Filtration in continuous-type scroll centrifuges

/ intermittent filtration in regular

centrifuges

Intermittent ion exchange in autoclaves at

high pressure and temperature


mixers

Intermittent impregnation

(possibly combined with ion exchange)


3



desalination


blendingIntermitten


mixers

Continuous impregnation (by analogy

with preparation of reforming

catalysts)

Continuous in regular or vacuum

belt furnaces

5Mechanical blending of metal

oxides and catalyst carrier

Blending of oxide composite material with (possibly ceramic) grinding

bodies in specified proportion (weight of grinding bodies / weight of blend)

In planetary grinderFormation of catalyst powder

in spray dryerBaking of formed catalyst under

specified regime

6 —

7 —

4

Mechanical grinding in planetary crushers

(preparation of water – distillation, ion-exchange

resins), possible ultrasonic crushing of

inoculant


blendingContinuous

Wet formation of bead catalyst in oil

column

Continuous in regular or vacuum

belt furnaces

Low Medium High High

х1 х1 х0,9 х0,7

х1 х1 х0,8 х0,6

х1 х1 х1 х1

80 80 90 95

Labor consumption


Capital Intensity

Productivity

Power consumption

Yield ratio, %

Technology for Preparat ion of Ox ide Cata lysts for Pyro lys is o f Hydrocarbons in to Carbon Nano-F ibers (CNF

Prod

uctiv

ity, t

ons

of fe

edst

ock

/ ton

s of

cat

alys

t per

hou

r

Labo

r con

sum

ptio

n (c

ompa

red

to

the

curr

ent v

alue

of F

isch

er-T

rops

ch

proc

ess)

Pow

er c

onsu

mpt

ion

(com

pare

d to

the

curr

ent v

alue

of F

isch

er-T

rops

ch p

roce

ss)

С5+

sele

ctan

ce, %

Pric

e, th

$/t


Catalyst Specifications

Capi

tal i

nten

sity

(com

pare

d to

the

curr

ent v

alue

for F

isch

er-T

rops

ch

(ORY

X =

1.5

mm

t of p

rodu

cts

per

year

, CAP

EX =

$10

00 p

er to

n pe

r ye

ar)

Stre

ngth

, kg/

mm

2

Serv

ice

cycl

e, m

onth

s

Pow

er c

onsu

mpt

ion,

Whr

/ton

of fe

edst

ock

Tota

l ser

vice

life

, yea

rs

Pric

e, th

$/t

Technical and EconomicCharacteristics of the

ProcessCatalyst Specifications

Capi

tal i

nten

sity

(com

pare

d to

the

curr

ent v

alue

for F

isch

er-T

rops

ch

(ORY

X =

1.5

mm

t of p

rodu

cts

per

year

, CAP

EX =

$10

00 p

er to

n pe

r ye

ar)

х0,8

х0,9

х01

х1

х0,9

х0,9

х1

х1

50 – 80

30 – 50

30 – 40

20 – 30

Multiple

Multiple

Single

Single

95

90

80

80

1

1,4

1,6

1,6

2015

2020

Catalyst:Powdered micron systems composed of

nickel and iron nano-particles

Process:Catalytic pyrolysis with

CNF yield

2010

2030

х0,9

х1

х1

—

х0,8

х0,9

х1

—

70 – 90

50 – 80

30 – 50

—

Multiple

Multiple

Single

—

80

80

70

—

1,6

1,4

1

—2010

2015

2020

Catalyst:Iron or nickel nano-dispersed

Process:Catalytic pyrolysis with

CNF yield

2030



centrifuges



centrifuges


Equipment for wet formation of bead catalysts

In planetary grinder (one-stage catalyst preparation: after

activation, powder does not need to be dried or baked)

In planetary grinder





Mechanical blending of metal oxides and catalyst carrier

Mechanical blending of metal oxides and catalyst carrier

Continuous impregnation (by analogy

with preparation of reforming

catalysts)





Development of industrial technologies for mechanochemical synthesis of catalysts

Formation of catalyst powder in spray dryer

Optimization of mechanochemical synthesis of catalysts for associated petroleum gas pyrolysis

Development of method to prepared catalysts with the use of massive metallic articles and alloys based on metals of 8th group

—— Normalized assessment of current parameter values. This assessment is used as the basis for future estimations of the same parameters in all analyzed sectors

Legend:


— Low-cost technology х1

High-capacity planetary grinders


With low content of

bonding agentIntermittent Intermittent ContactMechanical

grindingMechanical

blending2

Continuous Continuous ContactMechanical grinding

Mechanical blending3

With medium content of

bonding agent

Intermittent ContactlessUltrasonic grinding

Feedstock activation by

means of ultra sound or magnetic

radiation

4With low

content of bonding agent

Intermittent

Russian R&D

Nanotechnology Applications in Catalytic Petroleum Refining Processes. Isobutane-Butylene Alkylation


Catalyst Production TechnologiesZeolite-based

Processes and Catalysts (Compounds)



Crystallization Ion exchange Granulation, injection of

bonding agent

Drying and baking


Capital intensity ($ per ton of alkyl gasoline per year)

— 115 110 100

Medium Medium Low Low


— 190 180 170Power consumption (OPEX, $ per ton of alkyl gasoline per year)

Rejection rate, %


Labor consumption



grindingMechanical

blending


Technology

2020 203020152010


Leading edge


—

—

50%of Russian

market

60%of Russian

market

80%of Russian

market

Marketing

Quality

Ru

ss

ia

n

Ma

rk

et

Catalyst type:Y type (faujasite)

2020 203020152010

Number of units

Total capacity, kta



—

—

— —

1

50

10–15

0,5

3

550

110–165 6

9

1 750

350–525

18

Catalyst type:Fluorine hydride

2020 203020152010

Number of units

Total capacity, kta



—

—

— —

1

250

15–25

0,001

1

250

15–25

0,001

1

250

15–25

0,001

Catalyst type:Sulfuric acid

2020 203020152010

Number of units

Total capacity, kta



7

1 100

78–112 5

9

1 600

113–162

7

9

1 600

113–162 7

9

1 600

113–162 7

1

Research in effects of ultrasound or magnetic radiation, in particular MRET (Molecular Resonance Effect Technology), on feedstock activation and, subsequently, catalyst activity

Creation of demonstrational stand units to research continuous crystallization

Research in application of modern all-purpose disintegrators-activators

Creation of demonstrational stand units to research continuous ion exchange

Research in finding efficient bonding agent

Research in application of microwaves for contactless baking

Technical and Economic Characteristics of the Process (as per a ten-point scale)

Prod

uctiv

ity

Capi

tal I

nten

sity

Labo

r con

sum

ptio

n

Pow

er c

onsu

mpt

ion

Activ

ity(e

xter

nal

isob

utan

e : b

utyl

ene

mol

ar ra

tio

Sele

ctan

ce (o

ctan

e nu

mbe

r)

Pric

e, th

$/t


Process:Standard

2010

2015

2020

2030 7

7

7

7

6

6

6

6

4

4

5

6

7

7

7

7

10

10

10

10

96

96

96

96

0,05

0,05

0,05

0,05

Catalyst:Sulfuric acid

Process:Standard

2010

2015

2020

2030 7

7

7

7

6

6

6

6

4

4

5

6

7

7

7

7

10

10

10

10

96

96

96

96

0,05

0,05

0,05

0,05

Catalyst:Fluorine hydride

Process:Standard

2010

5

5

5

—

8

8

8

—

4

4

5

—

8

8

8

—

10

10

10

—

1,4

1,4

1,4

—

98

98

98

—

40

40

40

—

Catalyst:Y type (faujasite)

Technical and EconomicCharacteristics of the Process

(as per a ten-point scale)

Prod

uctiv

ity

Capi

tal I

nten

sity

Labo

r con

sum

ptio

n

Pow

er c

onsu

mpt

ion

Activ

ity(e

xter

nal

isob

utan

e : b

utyl

ene

mol

ar ra

tio

Sele

ctan

ce (o

ctan

e nu

mbe

r)

Pric

e, th

$/t


Crus

hing

stre

ngth

,

kg/m

m2

2030

2020

2015

Legend:



Consistent with platinum salt production method Lower production costs 2030 or later


TechnologyInjection of nano-sized precursor into the reaction system with subsequent

extraction of precursor from the reaction product and return into the process


Leading edge

Process:Standard

Process:Standard

Russian R&D

Nanotechnology Applications in Catalytic Petroleum Refining Processes. Production of Isopropyl Benzene


Technology for Preparation of Zeolite-Based Catalysts Processes and Catalysts (Compounds)




bonding agent

Drying and baking


Capital intensity ($ per ton of isopropyl benzene per year)

70 65 65 60

Medium Moderate Low Low


1,4 1,2 1,2 1,2Power consumption (OPEX, $ per ton of alkyl gasoline per year)

Rejection rate, %


2020 203020152010

Labor consumption


Leading edge

2020 203020152010



—

—

50%of Russian

market

50–80% share of Russian

market

100%of Russian

market

Marketing

Quality

Ru

ss

ian

Ma

rk

et


bonding agentContactMechanical

grindingMechanical

blending1

With low content of

bonding agentContactlessMechanical

grindingMechanical

blending2

ContinuousUltrasonic grinding

Feedstock activation

by means of ultra sound or magnetic

radiation

4 Continuous

INTERMITTENT INTERMITTENT CONTACTLESSULTRASONIC

GRINDING

FEEDSTOCK ACTIVATION BY

MEANS OF ULTRA SOUND OR MAGNETIC

RADIATION

3WITH LOW CONTENT OF

BONDING AGENT

2010

7

7

7

7

6

6

6

6

4

4

5

6

7

7

7

7

8

8

10

10

1,4

1,4

1,4

1,4

85

85

85

85

50

50

50

50

Te c h n i c a l a n d E c o n o m i c C h a r a c t e r i s t i c s o f t h e

P r o c e s s ( a s p e r a t e n - o i n t s c a l e )

Prod

uctiv

ity

Capi

tal I

nten

sity

Labo

r con

sum

ptio

n

Pow

er c

onsu

mpt

ion

Activ

ity (e

xter

nal

benz

ene

: pro

pyle

ne m

olar

ratio

Isop

ropy

l ben

zene

se

lect

ivity

, % w

ght

Pric

e, th

$/t


Crus

hing

stre

ngth

,

kg/m

m2

2030

2020

2015

Russ

ian

Alte

rnat

ive

Tech

nolo

gy

Catalyst type: Aluminum chloride (AlCl3)

2020 203020152010

Number of units

Total capacity, kta



4

600

4 200

23

2

300

2 100

11,5

1

150

1 050

5,7

—

—

— —

Wo

rld

Ma

rke

t

World Market

2020 203020152010

Total capacity, kta


12 600

800–1 300

15 300

1 000–1 500

17 300

1 100–1 700

18 000

1 200–1 800

Wor

ld A

ltern

ativ

e Te

chno

logy

Catalyst type: H3PO4 (phosphoric acid on carrier)

2020 203020152010

Number of units

Total capacity, kta


18

5 400

16 000

9

2 700

8 000

3

680

2 000

—

—

—

2010

8

8

8

8

5

5

5

5

4

4

5

6

6

6

6

6

5

5

6

6

1,4

1,4

1,4

1,4

90

90

90

90

60

60

60

60

Catalyst:MCM-22

2030

2020

2015

Catalyst:BETA zeolite

Catalyst type:BETA zeolite

2020 203020152010

Number of units

Total capacity, kta



—

—

—

—

2

300

19–30

1,25

3

450

29–45

1,9

3

450

29–45

1,9

Catalyst type:MCM-22

2020 203020152010

Number of units

Total capacity, kta



—

—

—

—

—

—

—

—

—

—

—

—

1

150

9–15

0,7

Continuous Continuous







Continuous Continuous



With low content of

bonding agent


Contactless


Legend:




With low content of


grindingMechanical

blending2

Continuous Continuous ContactMechanical grinding



bonding agent

Continuous ContactlessMechanical grinding


With low content of

bonding agentContinuous

Ru

ss

ia

n

Ma

rk

et

Wo

rld

Ma

rke

t

Wor

ld A

ltern

ativ

e Te

chno

logy

Technology Import

Russian R&D

Nanotechnology Applications in Catalytic Petroleum Refining Processes. Production of Ethyl Benzene

CATALYST MARKETS


Scientific and Technical Development

Catalyst Production TechnologiesZeolite-based

Processes and Catalysts (Compounds)




bonding agent

Drying and baking


Capital intensity ($ per ton of ethyl benzene per year)

75 70 65 60



1,6 1,4 1,4 1,2Power consumption (heat consumption, GJ per ton of ethyl benzene per year)

Rejection rate, %


2020 203020152010

Labor consumption

Technology

2020 203020152010



grindingMechanical

blending


Leading edge


—

—

20% of Russian market



Technology:AlCl3

2020 203020152010

Number of units

Total capacity, kta


Price, th$/t

Marketing

Quality

Russ

ian

Alte

rnat

ive

Tech

nolo

gy

Catalyst type:Aluminum chloride (AlCl3)

2020 203020152010

Number of units

Total capacity, kta



3

575

6 900–8 600

5,5

2

440

5 250–6 600

5,5

1

345

4 150–5 200

5,5

—

—

— —

Catalyst type:ZSM-5

2020 203020152010

Number of units

Total capacity, kta



1

230

7–8

40

—

—

— —

—

—

— —

—

—

— —

Catalyst type:BETA zeolite

2020 203020152010

Number of units.

Total capacity, kta



—

—

— —

2

450

8–11

50

3

542

11

50

3

542

11

50

Catalyst type:Transalkylation, type Y

2020 203020152010

Number of units

Total capacity, kta



—

—

— —

2

450

8–10

40

3

545

9–12

40

5

1100

19–24

40

Catalyst type:MCM-22

2020 203020152010

Number of units

Total capacity, ktaг



—

—

— —

—

—

— —

—

—

— —

2

545

11–13

60

Catalyst Type:Zeolite catalysts

2020 203020152010

Number of units

Total capacity, kta


52

21 700

660

58

23 700

720

64

26 200

800

70

28 700

870

17

6900

82,8–103,5

5,5

12

4900

58,8–73,5

5,5

6

2500

30–37,5

5,5

—

—

— —

1

Ultrasonic grinding



radiation

5 ContactlessWith low


IntermittentIntermittent

Equipment for feedstock activation by means of ultra sound or magnetic radiation

Ultrasonic grinding equipment

Technical and Economic Characteristics of the Process (as per a ten-point scale)

Prod

uctiv

ity

Capi

tal I

nten

sity

Labo

r con

sum

ptio

n

Pow

er c

onsu

mpt

ion

Activ

ity (e

xter

nal b

enze

ne :

ethy

lene

mol

ar ra

tio

Crus

hing

stre

ngth

,

kg/m

m2

Ethy

lene

ben

zene

sele

ctiv

ity, %

wgh

t

Pric

e, th

$/t


Process:Standard

2010

2015

2020

2030 5

5

5

5

8

8

8

8

4

4

5

6

8

8

8

8

10

10

10

10

1,4

1,4

1,4

1,4

80

80

80

80

40

40

40

40

Catalyst:Transalkylation,

type Y

Process:Standard

2015

2020

2030 5

5

5

5

8

8

8

8

4

4

5

6

9

9

9

9

8

8

8

8

1,4

1,4

1,4

1,4

80

80

80

80

40

40

40

40

Catalyst:ZSM-5 (pentasil)

Process:Standard

2010

2015

7

7

7

7

6

6

6

6

4

4

5

6

7

7

7

7

5

5

6

6

1,4

1,4

1,4

1,4

85

85

85

85

50

50

50

50

Catalyst:BETA zeolite

Process:Standard

2010

2015

2020

5

5

5

5

8

8

8

8

4

4

5

6

6

6

6

6

3

3

4

4

1,4

1,4

1,4

1,4

90

90

90

90

60

60

60

60

Catalyst:MCM-22

Исследования по влиянию ультразвука или магнитного излуче ния, в частности, технологии MRET (Molecular Resonance Effect Technology) на процесс активации сырья и вдальнейшем на активность катализатора

Continuous ContinuousUltrasonic grinding



radiation

6 ContactlessWith low








2010

2030

2020

2030





Legend: — High-quality production technology

