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© State Corporation “Russian Corporation of Nanotechnologies”, 2010
Executive Summary
to RUSNANO Board Meeting Scheduled for July 27, 2010 on the Issue of the
Roadmap to Nanotechnology Applications in Catalytic Petroleum Refining Processes
To be reviewed at RUSNANO Board Meeting scheduled for July 27, 2010 on the issue of the
Roadmap to Nanotechnology Applications in Catalytic Petroleum Refining Processes.
The Roadmap to Nanotechnology Applications in Catalytic Petroleum Refining Processes
(the "Roadmap") is a summary document describing the multi-layer system of strategic
development of the subject matter within a common timescale and showing parameters
that reflect economic efficiency of leading-edge technologies and products characterized by
a high demand potential and attractive consumer properties. The Roadmap is developed
based on the expert findings as well as the review of Russian and foreign analytic
materials.
The Roadmap describes the structure of demand for petroleum processing catalysts (the
"catalysts") and the changes taking place in the key performance characteristics of the
basic process equipment and installations where such catalysts are applied (depending on
the catalytic process layout) as well as in the key specifications of the most common types
of catalysts applied in such equipment and installations. The Roadmap shows alternative
technologies that can be used to produce the catalysts. It also gives an assessment of the
possibility to introduce in Russia different types of process lines capable to produce
catalysts whose key specifications would meet the competitiveness criteria.
For different catalyst production technologies, the Roadmap reflects the main R&D
directions pursued in Russia as well as the focal points in the import of technologies (types
of process equipment that needs to be procured from abroad). In view of the market pull
and technology push, the Roadmap gives the projection of strategic goals that can be
achieved by Russian catalyst producers in principle by the forecast horizon of 2030.
Subject Overview
Petroleum Processing Catalysts are defined as nano-structured substances that,
through a cycle of intermediate interactions, accelerate chemical reactions in petroleum
refining processes but are not themselves consumed in such reactions.
Catalysts are used in the majority of petroleum refining and petrochemical processes
playing the key role in their technology. Invention and introduction of new and
improvement of existing catalysts is the most promising direction of nanotechnology
developments in petroleum processing and petrochemical industries; this direction is seen
as the greatest contributor to solution of many problems in this sphere.
Nanotechnology Applications in Catalytic Petroleum Refining Processes Roadmap
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The Roadmap covers the five key petroleum processing technologies whose catalyst
markets are expected to have the highest volumes within the Roadmap forecast horizon:
1. Diesel fuel hydroskimming;
2. Catalytic cracking;
3. Light gasoline cut isomerization;
4. Catalytic reforming;
5. Hydrocracking.
Besides, the Roadmap deals with the four petrochemical processes which are wide-spread
in Russia and have the highest nanotechnology application potential:
1. Associated petroleum gas processing;
2. Isobutane-butylene alkylation;
3. Production of isopropyl benzene;
4. Production of ethyl benzene.
Petroleum Refining Industry Trends and Catalyst Market
In recent years, light petroleum products have been becoming more and more important
part of the world oil refining industry's product range. Production capacities of secondary
catalytic processes are growing rapidly. This trend is expected to persist exercising
significant influence on the industry's development patterns.
Another global trend expressed most prominently in the developed petroleum product
importing countries is the introduction of more stringent environmental norms and
standards. Such norms and standards are designed primarily to reduce polluting emissions
from fuel combustion as well as to improve quality of petroleum products (transition of the
EU countries to Euro-5 fuels with extra-low sulfur content).
Market analyses show that the main contributors to growth in demand for petroleum
products in Europe are distillate diesel fuels and high-quality gasolines which are the most
important merchandise of the petroleum refining industry. Gasoline consumption in the
U.S. and the Asia-Pacific region is also growing noticeably. Growth in demand for jet fuel is
less rapid while the market volume of fuel oil has started to shrink gradually.
According to expert estimations, the world market shares of petroleum processing catalysts
are distributed as follows: hydroskimming catalysts – about 40%; cracking catalysts –
30%; hydrocracking catalysts – 7%; reforming catalysts – 5%; other catalysts – 20%.
Annual catalyst product renewal rates are estimated at 15-20%.
Figure 1 below shows a forecast of the world market of catalyst for the five key oil refining
processes in monetary terms.
Nanotechnology Applications in Catalytic Petroleum Refining Processes Roadmap
© State Corporation “Russian Corporation of Nanotechnologies”, 2010
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Figure 1. World Market of Catalysts for the Most Promising
Oil Refining Processes
Diesel Fuel
Hydroskimming
Catalytic cracking
Hydrocracking
Light Gasoline Cut
Isomerization
Catalytic Reforming
$ b
ln
Diesel Fuel
Hydroskimming
Catalytic cracking
Hydrocracking
Light Gasoline Cut
Isomerization
Catalytic Reforming
$ b
ln
Development of the world catalyst market within the Roadmap forecast horizon is expected
to be affected by the following major trends:
Diesel fuel hydroskimming:
Total diesel fuel hydroskimming capacity will grow by 25% by 2030;
Consumption of sulphide diesel fuel hydroskimming catalysts is expected to grow both
in physical and monetary terms;
Catalyst prices will generally remain stable at the current level.
Catalytic cracking:
Total catalytic cracking capacity will remain at the current level up to 2030;
Consumption of cracking catalysts is expected to grow slightly;
The market volume in monetary terms will grow significantly by 2030 due to anticipated
increase in catalyst prices.
Light gasoline cut isomerization:
By 2030, the world isomerization catalyst market is expected to grow by 40-50%;
The most advanced and promising technology in this sphere is the low-temperature
isomerization.
Nanotechnology Applications in Catalytic Petroleum Refining Processes Roadmap
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Catalytic reforming:
By 2030, total reforming capacity is expected to grow by 20%;
The most advanced technology in this sphere is the moving-bed catalytic reforming;
Annual consumption of catalysts will grow both in physical (capacity expansion) and
monetary (accelerated price growth) terms.
Hydrocracking:
Hydrocracking is one of the most promising technologies: by 2030, hydrocracker
capacity is expected to double in size;
Annual catalyst consumption is also expected to double.
Russian Petroleum Refining industry and Catalyst Market
In recent years, the Russian petroleum refining industry is showing obvious improvements
reflected both in growth of processing volumes and gradual increase in quality of motor
fuels. A number of Russian oil refineries are being upgraded to incorporate new oil
processing facilities with higher conversion ratio some of which have already been
commissioned.
The basis of the Russian petroleum refining industry is formed by 27 large oil refineries
whose total throughput is 260 mta which is 95-98% of all petroleum processed in Russia.
In 2009, primary processing throughput of Russian refineries was about 236 mt.
However, the Russian petroleum refining industry lags significantly behind the same
industries of the developed countries. The main problems faced by the Russian petroleum
refining industry include:
Poor oil conversion performance (small share of secondary oil refining processes);
Relatively low quality of produced petroleum products;
Obsolete production pattern;
High degree of deterioration of production facilities and equipment;
Low energy efficiency / high power consumption.
Because of their poor conversion performance, Russian oil refineries are currently utilized
by 70-75% of their design capacity while today's strong demand and high prices for
petroleum products ensure that utilization of a typical world-class refinery is close to 100%
(e.g., average oil conversion rate in Russia is 66-72%, in Europe – 86-88%, in the U.S. –
89-92%).
Nanotechnology Applications in Catalytic Petroleum Refining Processes Roadmap
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The range of petroleum products exported by the Russian petroleum refining industry is
dominated by low-value commodities including straight-run gasoline, vacuum gasoil, low-
quality (compared to European standards) diesel fuel with relatively high sulfur content,
fuel oil, base oils. The share of high-value petroleum products is very small.
One of the gravest problems currently faced by the Russian petroleum refining industry is
the high degree of deterioration of production facilities and equipment estimated at 80% as
well as the use of obsolete energy-consuming and uneconomical technologies (in six of the
thirteen Russian catalytic crackers, the obsolete bead-catalyst units are used). This results
in high energy costs and low economic efficiency of the Russian petroleum refining
industry. In active Russian refineries, per-unit energy consumption is two-three times
higher than the one in foreign installations.
The serious problems related to uneven distribution of large-scale oil refineries in Russia
contribute to growth of the number of small-scale refineries (as of now, over 150
installations) with throughputs ranging from 10 to 700 kta. These days, such small-scale
refineries produce about 2-5% of all Russian petroleum products. As a rule, small-scale
refineries are involved in low-margin refining of crude oil at a very poor conversion ratio.
Operation of such refineries is typically very harmful for the environment.
Nevertheless, in recent years there has been a general trend to improvement across the
Russian petroleum refining industry manifesting in:
Considerable increase in investments of Russian oil companies in petroleum refining
facilities;
Growth in petroleum refining volumes;
Gradual improvement in quality of produced motor fuels due to cease of production of
leaded gasoline;
Increase in the share of high-octane gasoline and environmentally friendly diesel fuel.
However, these positive trends have virtually nothing to do with Russia's own R&D
achievements. The majority of technologies and equipment used in Russian refineries are
procured from the leading western manufacturers which also supply to the Russian market
up to 55-70% of all petroleum processing catalysts. Annual catalyst market renewal rate in
Russia is about 4%.
Figure 2 below shows a forecast of the Russian market of catalyst for the five key oil
refining processes in monetary terms.
Nanotechnology Applications in Catalytic Petroleum Refining Processes Roadmap
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Figure 2. Russian Market of Catalysts for the Most Promising
Oil Refining Processes
Diesel Fuel
Hydroskimming
Catalytic
cracking
Hydrocracking
Light Gasoline Cut
Isomerization
Catalytic
Reforming
$ m
ln
Diesel Fuel
Hydroskimming
Catalytic
cracking
Hydrocracking
Light Gasoline Cut
Isomerization
Catalytic
Reforming
$ m
ln
Development of the Russian catalyst market within the Roadmap forecast horizon is
expected to be affected by the following major trends:
Diesel fuel hydroskimming:
Total hydroskimmer capacity is expected to grow steadily;
Increase in production capacity will be due mainly to wider application of alumina-
supported cobalt-molybdenum catalyst;
By 2030, experts predict introduction of the crucially new catalyst production
technology based on oxidation reactions;
By 2030, development of a new type of catalyst carrier (e.g., nano-structured titanium
dioxide) is anticipated.
Catalytic cracking:
According to experts, total catalytic cracking capacity will grow steadily;
By 2030, all bead-catalyst crackers will be decommissioned;
Increase in cracking capacity will take place mainly due to wider application of
microspheric aluminosilicate zeolite-containing catalysts with average particle sizes of
10 to 150 mkm.
Nanotechnology Applications in Catalytic Petroleum Refining Processes Roadmap
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Light gasoline cut isomerization:
By 2030, the number of isomerization plants in Russia is expected to double and reach
30;
Catalyst consumption is expected to increase significantly both in physical and
monetary terms;
Catalyst prices are predicted to grow due to elevation of prices for precious metals.
Catalytic reforming:
Total reforming capacity will grow significantly by 2030;
In the near future, the industry will see a massive replacement of existing obsolete
equipment to new modern installations;
Capacity growth will be in large part related to the growth in the number of oxide
catalyst installation;
Catalyst prices are predicted to grow due to elevation of prices for precious metals.
Hydrocracking:
In Russia, this process is not yet widely applied;
By 2030, the number of hydrocrackers in Russia is expected to reach seven;
Catalyst prices up to 2030 are not predicted to change substantially;
Strategic Goals of Russian Producers
The Roadmap covers the five key petroleum processing technologies whose catalyst
markets are expected to have the highest volumes within the Roadmap forecast horizon.
Table 1 below contains strategic goals recommended for Russian catalyst producers that can
be achieved within the Roadmap forecast horizon.
Nanotechnology Applications in Catalytic Petroleum Refining Processes Roadmap
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Table 1
Strategic Goals of Russian Catalyst Producers
Die
sel
fuel
hyd
roskim
min
g
Cata
lyti
c c
rackin
g
Isom
eri
zati
on
Cata
lyti
c
refo
rm
ing
Hyd
ro
crackin
g
20
10
20
15
20
20
20
30
20
10
20
15
20
20
20
30
20
10
20
15
20
20
20
30
20
10
20
15
20
20
20
30
20
10
20
15
20
20
20
30
Marketing
80-100% share of Russian market
60-80% share of Russian market 65 80 80 65 80 65
40-60% share of Russian market 40 50 60 50 50 50 50
20-40% share of Russian market 30 30 40
Up to 20% of Russian market 20 20 – –
Quality
Leading edge + + + + + + + + + + + + + +
Slightly lagging behind the leaders + + +
Lagging behind the leaders + – –
Technology
Introduction of Russia's own full-
cycle catalyst production
technology
+ + + + + + + + + + + + + + + +
Application of purchased foreign
technologies + + + +
Main Directions of R&D Activities and Technology Import
According to study findings, in order to overcome the current technological backwardness
and make Russian catalysts a competitive commodity on the domestic market a package of
measures needs to be implemented:
Drafting and accomplishment of Russia's own R&D plans in the key research
directions;
Arrangement of technology import (procurement of process equipment) required for
comprehensive modernization of production facilities.
The key directions of Russia's own R&D activities and groups of key process equipment
recommended to be procured from abroad are listed in Table 2 below.
Nanotechnology Applications in Catalytic Petroleum Refining Processes Roadmap
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Table 2
Own R&D and Imported Technologies Required to Promote Catalyst
Production in Russia
Diesel fuel Hydroskimming
Own R&D Technology Import
Development of sulphidation regimes Complete process lines
Optimization of drying conditions
Development of bimetallic compound
synthesis methods
Development of activation technologies
and equipment
Development of methods to control
carriers' honeycomb structure
Development of active component
synthesis technologies
Development of oxidative
desulfurization technologies
Catalytic Cracking
Own R&D Technology Import
Optimization of baking conditions Pulp filtration (centrifugal separation)
equipment
Development of compound
homogenization technologies
Baking equipment (including drum
furnaces) and filters
Development of technologies for baking
in controlled gas environments
Spray drying equipment
Development of catalysts resistant to
metal poisoning (vanadium, nickel) to
process fuel oil
Zeolite synthesis equipment
Synthesis of various types of zeolite,
including those with wide mesopores,
for catalytic cracking of heavy crude oil
and for the "mili-second" process
Thermocouple stabilization equipment
Blending equipment
Matrix modification
Nanotechnology Applications in Catalytic Petroleum Refining Processes Roadmap
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Light Gasoline Cut Isomerization
Own R&D Technology Import
Development of methods for
simultaneous application of precious
metals and sulfate
Equipment for wet formation of bead
catalyst in oil column
Improvements in wet formation of bead
catalyst in oil column
Scroll centrifuges for continuous filtration
and washing of wet synthesized products
Development of technologies for
catalyst granulation without binding
agents
Belt-type baking furnaces for continuous
baking at temperatures up to 600 С
Improvement of continuous zeolite
synthesis technology
Agitating autoclaves with a heating range
of up to 200 С for zeolite synthesis
Catalytic Reforming
Own R&D Technology Import
Development of catalysts with
improved mechanical strength and high
catalytic activity for moving-bed
installations
Carrier production equipment
Development of catalysts ensuring high
octane numbers at smooth processing
regimes
Drying equipment
Development of hydrogen yielding
catalysts
Equipment for reduction in hydrogen
stream
Hydrocracking
Own R&D Technology Import
Development of technologies to form
catalysts in solutions of bimetallic
compounds with particle sizes of about
1 nm
Equipment for catalyst impregnation
(fixation of bimetallic compounds on
carrier surface)
Main Conclusions
Nanotechnology Applications in Catalytic Petroleum Refining Processes Roadmap
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By results of the studies performed, the following main conclusions can be drawn:
With respect to catalyst production technologies:
On the horizon of up to 2030, no radical changes in the catalyst production
technologies portfolio are expected;
Technology improvements and developments will be localized mainly in separate
process stages or technical methods;
Russian catalyst production technologies generally lag behind the world leaders
(obsolete equipment, low capacity utilization);
The major bottleneck in the chain of development and application of Russian
catalysts is the transition from R&D stage to industrial implementation. Russian R&D
institutes are substantially short of pilot production facilities which makes them
unable to prove scalability of their solutions. This problem could be solved through
introduction of large engineering centers.
With respect to oil refineries' demand for catalysts:
Petroleum conversion ratio needs to be increased through improvement and wider
application of cracking processes. This would allow releasing more crude oil for
export abroad;
Introduction of more stringent regulatory requirements to motor fuels, transition to
Euro-4 and 5 standards highlight the need for production of cleaner fuel. To produce
such cleaner fuel, sulfur content will be reduced mainly by means of hydroforming
processes.
With respect to Russian catalyst production development prospects:
Russia has a number of promising newly developed technologies whose level is not
lower and sometimes even higher than those of the world leaders;
These technologies can be recommended for industrial implementation including with
RUSNANO support;
The most efficient form of such support would be participation in the establishment
of special-purpose engineering companies intended to design package solutions for
oil refineries on the basis of R&D findings.
Roadmap Visualization Description
Presented below, is the Roadmap structure with its main elements outlined.
Nanotechnology Applications in Catalytic Petroleum Refining Processes Roadmap
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Figure 3. Roadmap Structure
The Roadmap visualization includes four major sections (see Figure 3):
A Scientific and Technical Development
B Catalyst Production Technologies
C Processes and Catalysts (Compounds)
D Catalyst Markets
The Roadmap visualization illustrates the correlations between the key technologies which
the catalyst production industry relies on, the existing and future catalysts and their
characteristics, the behavior of Russian and world catalyst markets.
A short description of the Roadmap sections is given below.
Section A. Scientific and Technical Development
The Section includes:
1. Process equipment and systems needed to be procured from abroad to promote catalyst
production in Russia;
2. The most promising R&D directions recommended to be pursued in Russia within the
Roadmap horizon (up to 2030) to revive development and production of Russian
catalysts.
Section B. Catalyst Production Technologies
This sections describes the main catalyst production technologies.
For all technologies described in the Roadmap this Section gives an assessment of current
values of their key technical and economic characteristics as well as a forecast of their
changes within the Roadmap horizon.
The Section also gives a description of existing or advanced catalyst production process
lines for each of the analyzed technologies.
Section C. Processes and Catalysts (Compounds)
Nanotechnology Applications in Catalytic Petroleum Refining Processes Roadmap
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This Section deals with the main types of catalytic processing equipment and catalysts used
in such equipment. To be included in this Section, a "process-catalyst" system must have a
significant portion of realized nanotechnology applications.
Section D. Catalyst Markets
This Section gives an assessment and forecast of the basic behavioral parameters of the
catalyst market as of today and within the Roadmap horizon.
It also reviews the topmost strategic goals of Russian catalyst producers that can be
achieved within the specified timeframe.