Opportunities for New Products Development in Green Chemistry. José Marcos Ferreira Tainá Dias Valente
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1 Opportunities for New Products Development in Green Chemistry José Marcos Ferreira Tainá Dias Valente
2 Summary 1 Fábrica Carioca de Catalisadores S.A. FCC S.A. 2 Our Product 3 Innovation 4 Technology Assessment and Opportunities 5 Conclusions
3 FCC S.A.
4 Our Commitment % 59% do mercado Sul Sul Americano* Mission: Funcionários FCC S.A. Próprios* mission is to provide catalysts, additives and solutions for the Volume oil, de de vendas* chemical and petrochemical industries t Vision: Our vision is to be acknowledged as a high technology, market leader company, operating ethically and in a profitable, competitive, environmentally friendly and socially responsible way. Faturamento Faturamento R$379 R$379 Milhões* Milhões*
5 FCC S.A. Overview Three-party venture established in 1985 Petroquisa, Akzo & Oxiteno
6 Fábrica Carioca de Catalisadores S.A
7 FCC S.A. in Rio 80 km Very close to the Rio you know!
8 Markets Served * Funcionários Próprios* Market Share 67% 59% South American market* do mercado Sul Americano* t Sales Volume de vendas* Revenues Faturamento R$379 R$379 Million* Milhões* The only FCC catalyst manufacturer in South America
9 Our Product
10 FCC Catalyst Basic Composition Synthetic Matrix Silica Responsible for binding ingredients. Active Component Zeolite Imparts activity and selectivity to the catalyst. Inert Matrix Kaolin Influences catalyst physical properties. No activity. INERT MATRIX Other Components can be used as additives or embedded in the particle. Active Matrix Aluminas Pre-cracking of large molecules.
11 FCCU Simplified Regenerator Catalyst Make-up Flue Gas Reactor Products Dry Gas (C 2- ) LPG (C3-C4) Gasoline (naphtha) Light Gas Oil (LCO) Heavy Gas Oil (HCO) Slurry Air Riser Feed
12 FCCU in operation
13 Innovation
14 Global FCC Technological System Integration of FCC S.A. and ALBEMARLE technological systems Agreements and cooperation in R&D with Science & Technology Institutions. Global exchange of knowledge Competitive Advantage USA
15 Research & Development Stage Gate methodology for Novel Products Development and Technological Innovation. MARKET PLANT TRIAL PROTOTYPE PLANT PILOT PLANT CATALYTIC EVALUATION: ACE/MAT/FST ANTICIPATION OF MARKET DEMANDS
16 Technology Management Program MARKET INTELLIGENCE R&D PRODUCT DEVELOPMENT TECHNICAL SERVICE CUSTOMER NOVEL PRODUCT Profitability maximization results from customer involvement in the early stages of product development and technological knowledge inputs from R&D centers. GREATER PROFITABILITY FOR THE CUSTOMER
17 Technology Assessment and Opportunities
18 # Articles Technology Assessment Technical Papers on Heteregeneous catalyst and biofuels 600 Matériaprima 500 Produção Embalagem Distribuição Consumo Disposição final Source: sciencedirect.com
19 Technology Assessment - Potential Applications Catalysts Zeolites Distribuiç ão XTL Catalyst (Fischer-Tropsch) Solid base/acid support Heterogeneous trasesterification Fuel Quality (Biodiesel) Lignocellulosic Biomass Conversion Purification of gas streams Catalytic fast pyrolysis / bio-oil upgrading Aluminas Distribuiç ão Etherification Distribuiç ão Effluent treatment
20 Potential products Pyrolysis oil (bio-oil) Biofuels Octane booster Surfactants Solvents Emulsifiers Monomers
21 Opportunities: FCC S.A. PROCAT Partnership PROCAT Unidade Protótipo de Catalisadores Catalyst Prototype Unit Multi-purpose pilot plant for the scale-up and manufacture of catalysts, adsorbents and related products. PROCAT is part of the Federal University of Rio de Janeiro (UFRJ), but it can provide R&D services on a multi-client basis. Assets: ca. 10 MMUS$ investment in infra-structure and equipment Location: opposite to FCC SA.
22 Capabilities: FCC S.A. PROCAT Partnership Available equipment Drying system Spray Dryer Bead mills Atmospheric and pressurized reactors (autoclaves) - bench and pilot scales Finishing and shaping area: extruders, coating pan Rotary Calciner and kilns Solids blender Vacuum filters Synthesis laboratory Physico-chemical characterization: chemical composition, physisorption, crystallography, particle sizers. Source: procat-ufrj.com/index.php/home/
23 FCC S.A. & PROCAT Capabilities Active Ingredients Zeolites: Y, ZSM-5, Beta, Ferrierite Aluminas Aluminossilicates Products Catalysts for fluid & fixed bed Adsorbents Support for active phase Unit operations: Ion exchange Metals impregnation Catalyst shaping
24 Business Opportunities Joint development of catalysts for new/existing processes Product scale-up: bench, pilot, industrial Product characterization Toll manufacture of catalysts and adsorbents
25 Conclusions
26 Conclusions The expertise of FCC S.A. to make catalysts for the fluid catalytic cracking process can be used to make green chemistry products ; A number of FCC S.A. intermediate products can be used to formulate products for other industries; PROCAT facilities are available for product development at bench and pilot plant scale; Cost-effective and timely option for product development, characterization and commercial production; R&D activities under contract and secrecy agreement; FCC S.A. is open for joint development of heterogeneous catalysts and adsorbents for new processes; FCC S.A. welcomes partners in new business development in association with PROCAT: JVs, toll manufacture, new products & services.
27 Thank you!
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