Opportunities for New Products Development in Green Chemistry

José Marcos Ferreira

Tainá Dias Valente

Summary

Fábrica Carioca de Catalisadores S.A. – FCC S.A. Our Product Innovation Technology Assessment and Opportunities Conclusions

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FCC S.A.

Our Commitment

250 Funcionários

Próprios*

59% do mercado

Sul Americano*

Volume de vendas*

32.694t

R$379 Milhões*

Faturamento

67% do mercado

Sul Americano*

Volume de vendas*

32.694t

R$379 Milhões*

Faturamento

Mission: FCC S.A. mission is to provide catalysts, additives and solutions for the oil, chemical and petrochemical industries.

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.

FCC S.A. Overview

1988 1993 1995 2002 2004 2004 2009 2012 2013 2016

1985 2017

Three-party venture

established in 1985

Petroquisa, Akzo & Oxiteno

Fábrica Carioca de Catalisadores S.A.

1988 1993 1995 2002 2004 2004 2009 2012 2013 2016

FCC S.A. in Rio

80 km

Very close to the Rio you know!

Markets Served

250 Funcionários

Próprios*

59% do mercado

Sul Americano*

Volume de vendas*

32.694t

R$379 Milhões*

Faturamento

*2016

67% South

American market*

Market Share

Sales 32.694t

R$379 Million*

Revenues

The only FCC catalyst manufacturer in South America

Our Product

FCC Catalyst Basic Composition

INERT MATRIX

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.

Active Matrix Aluminas Pre-cracking of large molecules.

Other Components can be used as additives

or embedded in the particle.

Air

Flue Gas

Feed

Products

Regenerator

• Dry Gas (C2-)

• LPG (C3-C4)

• Gasoline (naphtha)

• Light Gas Oil (LCO)

• Heavy Gas Oil (HCO)

• Slurry

FCCU Simplified

Riser

Catalyst Make-up

Reactor

FCCU in operation

Innovation

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

Research & Development

MARKET

ANTICIPATION OF MARKET DEMANDS

PLANT TRIAL

PROTOTYPE PLANT

PILOT PLANT

CATALYTIC EVALUATION: ACE/MAT/FST

Stage Gate© methodology for Novel Products Development and Technological Innovation.

Technology Management Program

NOVEL PRODUCT

GREATER PROFITABILITY FOR THE CUSTOMER

MARKET INTELLIGENCE

PRODUCT DEVELOPMENT

R&D

TECHNICAL SERVICE

CUSTOMER

Profitability maximization results from customer

involvement in the early stages of product development and

technological knowledge inputs from R&D centers.

Technology Assessment and Opportunities

Technology Assessment

Disposição final

Consumo Distribuição Embalagem Produção Matéria-prima

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400

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600

2009 2010 2011 2012 2013 2014 2015 2016 2017

# A

rtic

les

Technical Papers on “Heteregeneous catalyst and biofuels”

Source: sciencedirect.com

XTL Catalyst (Fischer-Tropsch)

Fuel Quality (Biodiesel)

Heterogeneous trasesterification

Purification of gas streams

Catalytic fast pyrolysis / bio-oil upgrading

Zeolites

Catalysts

Distribuição

Solid base/acid support

Lignocellulosic Biomass Conversion

Aluminas

Technology Assessment - Potential Applications

Distribuição Effluent treatment

Distribuição Etherification

Potential products

Pyrolysis oil (bio-oil)

Biofuels Octane booster

Surfactants Solvents Emulsifiers

Monomers

Opportunities: FCC S.A. – PROCAT Partnership

• 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.

PROCAT – Unidade Protótipo de Catalisadores – Catalyst Prototype Unit

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/

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

Business Opportunities

• Joint development of catalysts for new/existing processes

• Product scale-up: bench, pilot, industrial

• Product characterization

• Toll manufacture of catalysts and adsorbents

Conclusions

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.

Thank you!

josemarcos@fccsa.com.br