“perspective on refining and petrochemicals catalysis at nanoscale“ · 2003-07-23 · trends in...
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© 2003, Exxon Mobil Corporation All Rights Reserved
““Perspective on Refining and Perspective on Refining and
Petrochemicals Petrochemicals
Catalysis at Catalysis at NanoscaleNanoscale““
S. Mark DavisS. Mark Davis
NSF Catalysis WorkshopNSF Catalysis Workshop
June 19-20, 2003June 19-20, 2003
950 Million
Gallons Per Day (World Wide)
3.2 Billion 1.8 Billion
CrudeProduction
Refining &Chemicals Fuel
Gasoline
Diesel
850 MillionToday’s Infrastructure• Massive• Global• Highly Efficient• 100 Years in Making
Large and Complex Industry
300 Million
Chemicals
Trends in Refining Catalysis
Trends: Improved selectivityEnergy efficiencyBetter utilization of hydrocarbonsUtilization of unconventional feedstocksCombined reaction and separationIntermaterial substitution
“Refinery of the Future” or “Energy Plants”– Distributed Power Production– Flexible Feedstock– Flexible Product Production
Energy Efficiency Focus
ProductRegulationFocus
Short-term
Medium-term
Longer-term
Tailored Structure andStructure Property Control atNanoscale Important for Next
Generation Catalysts
High Throughput Methods ChangingR&D Work Process
Analysis
Experimental Design
Automation &Robotics
High SpeedAnalysis
DatabaseManagement
Informatics
Robotics
Analytics 12
34
56
AB
CD
EF G I0.E+00
4.E+05
8.E+05
1.E+06
2.E+06
Mw
Activator Catalyst
60Å
100Å
20Å
40Å
Zeolite YZSM-5
Pore Size A
406080100
5
10
20
MCM-41
Gasoil ResidsGasolineChemicals
°
Shape Selective Catalysis Key toManaging Molecular Size & Shape
• MCM-41 Commercial Catalytic Nanotechnology Example
• Exciting New EM Materials Now Entering Pipeline
© 2003, Exxon Mobil Corporation All Rights Reserved
Surfactant Micelle
Micelle RodHexagonal Array
Calcination
MCM-41
Silicate
MCM-41: What Is It?
Clad the Surface
Vary ChemicalComposition
Vary Pore Size1.5nm to >10nm
Anchor Metalsand Catalysts
Many Options for Tailoring Microstructure
and Reactivity
SCANfining™ Leading CatNaphtha (Gasoline)Desulfurization Process- Removes sulfur, No Vol. Loss- Minimizes Octane Loss
- 28 Units Planned/Operating
Nebula™ Superior Catalystfor Diesel Processing– Most Active Catalyst Known– Lowers Investment to Meet
Low-Sulfur Diesel
SCANfining™ Catalyst RT-225
Maximize HDS
S+H2 +H2S
+H2
Minimize Olefin Saturation
Achieving Lower FuelSulfur Levels
© 2003, Exxon Mobil Corporation All Rights Reserved
0 KF-843 DN-190 KF-848 "Nebula"™
Relative Volume Activity, %
0
Site Property Control in Powders and Pellets Via Synthesis Strategies
....
....
Non Classical Synthesis:- Produce new or metastable catalyst precursors [hydrotreating]- Structure directing methods, epitaxy control
Modifying Site Functionality: - Acid site strength and density, promoters, multifunction systems
Morphology and Distribution: - Site placement in specific environments--pellets or powders - Metals, compounds, promoters
Lessons Learned
• The Hard Part Isn’t Discovery…It’s Development and Commercialization
• Partnerships, High Throughput Methods, and Modeling AreDecreasing Cycle Times to Commercialize Breakthrough R&D
- Oil-Auto Examples Aftertreatment and On-Board Reforming
• Coupling Nanotechnology Developers with ApplicationsDevelopers is Essential
- Academic Spin-Off Companies- Established Technology Suppliers- National Laboratories- Iterate/Optimize with Technology Users
• Evolving Industrial Research LandscapeWill Likely Lead to More Multi-Party Cooperation
Hybricats: Vision for theFuture
Today’s Capabilities
Shape SelectiveZeolites
High ActivityMetal Oxide
Nano-structures
CombineBest
Features
•Higher Activity/Selectivity•Poison Tolerant/Longer Life•Improved Regenerability•Combined Reaction/Separation
Tomorrow’s CatalystsTailored MultifunctionZeolite--Metal Oxide Hybrids
© 2003, Exxon Mobil Corporation All Rights Reserved