© 2008 aker solutions working together on a mercury-free vcm catalyst inc3. nairobi. 30 october...
TRANSCRIPT
© 2008 Aker Solutions
Working together on a mercury-free VCM catalyst
INC3 . Nairobi . 30 October 2011
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© Johnson Matthey and Jacobs
Agenda
■ Jacobs and Johnson Matthey
■ Background
■ History of catalyst development
■ Key features of mercury-free VCM catalyst
■ Current achievements
■ Future milestones
■ Estimated catalyst cost
■ Conclusions
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© Johnson Matthey and Jacobs
Jacobs and Johnson Matthey
■ Jacobs● Founded in 1947● Publicly traded company● Leading provider of professional, technical and construction services● Acquired part of Aker Solutions in 2011● Revenues [2010] of $ 9.9 billion
■ Johnson Matthey● Founded in 1817● Publicly traded company● Speciality chemicals company; core skills in catalysis, precious metals● Sales (excluding precious metals) [2010] of £ 2.3 billion
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© Johnson Matthey and Jacobs
Background
■ In the acetylene based PVC process, acetylene and hydrogen chloride (HCl) are reacted over mercury based catalysts to form Vinyl Chloride Monomer (VCM) which is polymerised to PVC
■ The production, use and recycling of mercury catalysts causes significant mercury emissions to the environment
■ Jacobs and Johnson Matthey have jointly developed a novel mercury-free catalyst for this process
● Being tested in a pilot plant at a leading Chinese VCM manufacturer
coalcalcium carbide
acetylene + HCl VCM PVCcatalyst:
mercury on carbon
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© Johnson Matthey and Jacobs
History of catalyst development
■ In 1995, Jacobs developed a mercury-free VCM catalyst and tested it successfully on pilot plant scale
● Longer catalyst life (vs mercury catalyst) confirmed
■ Catalyst was never commercialized because Middle East project was terminated
■ In 2006, Jacobs and Johnson Matthey started cooperation to further develop and commercialize a mercury-free catalyst
● Customized to Chinese process conditions
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© Johnson Matthey and Jacobs
Key features of mercury-free VCM catalyst
■ Non toxic and non hazardous for environment
■ Precious metal on carbon
■ Can be used with no or minimal changes to existing process
■ Better performance than mercury catalyst
● Longer life time● Less catalyst required
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© Johnson Matthey and Jacobs
Current achievements
■ 2006 Start catalyst design phase
■ 2007 Start laboratory phase
■ 2009 Achieved laboratory phase targetsCatalyst ready for pilot plant
■ 2010 Cooperation agreement with leading Chinese PVC producer for industrial tests
■ Status October 2011● Significant improvement in catalyst performance● Patent applications filed● Started pilot test in VCM plant of Chinese partner
■ Running since end of June■ Excellent performance
● Preparations for commercial test in progress● Finished design for new catalyst plant in China● Catalyst cost model well defined
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© Johnson Matthey and Jacobs
Future milestones
■ Aim to start commercial test early 2012● Test deemed successful after 6 months stable operation, meeting
performance criteria (mid 2012)● Afterwards, reactor will continue to run on catalyst until end of life time
■ If commercial test is successful, initial small quantities of catalyst can be available within one year (mid 2013 earliest), for further evaluation
■ Start building new catalyst plant in China
■ Development complete delivery model including catalyst loading and unloading, start-up and recycling services
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© Johnson Matthey and Jacobs
Estimated catalyst cost
■ Current mercury catalyst cost● <1% of total PVC production costs*● costs to minimize mercury emissions
not included
■ Estimated mercury-free catalyst costs● <2% of total PVC production costs*
■ Precious metal can be either purchased or leased
■ Precious metal recycling included in cost estimates
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© Johnson Matthey and Jacobs
Conclusions
■ Novel mercury-free VCM catalyst under development
● Non toxic and non hazardous for the environment
● Development started in 1995
● Started customization to Chinese process conditions in 2006
● Excellent pilot plant performance at leading Chinese VCM manufacturer
● Aim to start commercial test early 2012
● Minimal impact on total PVC production costs expected
Our target is to provide an environmentally and economically sustainable mercury-free catalyst to
the Chinese PVC manufacturing industry
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© Johnson Matthey and Jacobs
Contact us
For any questions regarding this development program please contact:
Bas van HaandelJacobs The Netherlandsphone: +31 71 5827992email: [email protected]
Erwin TeirlinckJohnson MattheyUnited Kingdomphone: +44 1763 253019email: [email protected]
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© Johnson Matthey and Jacobs