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Global Markets for Catalysts: Focus on Catalyst Regeneration

Global Markets for Catalysts: Focus on Catalyst Regeneration

The global market for catalyst and catalyst regeneration reached nearly $23.2 billion and nearly $24.6 billion in 2013 and 2014, respectively. This market is forecasted to grow at a compound annual growth rate (CAGR) of 4.0% to reach $29.9 billion in 2019.

This report provides:

An overview of the global markets for catalysts with a focus on catalyst regeneration.

Analyses of global market trends, with data from 2011 to 2014, and projections of CAGRs through 2019.

An understanding of how the regenerated catalyst business contributes to meeting the energy needs of the world's economies while at the same time helping to reduce the costs associated with preventing environmental degradation and remediation of adverse environmental impacts as they occur.

Information on the main regeneration markets of refineries, chemical applications and flue/waste treatment systems.

Assessment of market impact due to rising raw material prices and tight supply and demand curves.

Evaluation of the role of catalyst regeneration as a key input for the production of high-quality, clean transportation fuels, and environmental cleanup of dangerous pollutants.


SCOPE AND FORMAT

Meeting rising energy requirements and protecting the environment are among the most important applications of catalyst technology. Broadly speaking, a catalyst is a substance that increases the rate of a chemical reaction by reducing the required activation energy, but is left unchanged by the reaction.

As was the case in the previous review on this topic, the refinery industry remains the largest single user of regenerated catalysts, especially in hydroprocessing to produce refined products such as gasoline and low-sulfur diesel fuel.

Regenerated catalysts find use in many types of environmental remediation, from power plant emissions control systems to industrial effluent and municipal waste treatment. Regenerated catalysts lower costs, since they can be significantly cheaper than fresh catalysts and nearly as active.

This report provides an understanding of how the regenerated catalyst business contributes to meeting the energy needs of the world economies, while at the same time helping reduce the costs associated with preventing environmental degradation and remediation of adverse environmental impacts as they occur.

While the core focus of the report is catalyst regeneration, we also review the global catalyst market and provide forecasts for various segments, as the catalyst market trends strongly drive the regeneration market trends.

The study is divided into a number of sections and covers the following aspects, each covered in separate chapters:

Catalysts, the catalyst market scenario and projections.
Catalyst regeneration technology by application.
Elements involved in the processes in catalyst regeneration.
Regulatory aspects affecting the catalyst regeneration marketplace.
Catalyst regeneration market scenarios and projections.
Analysis of patents in catalyst regeneration.
Company profiles for market participants.

CHAPTER 1 INTRODUCTION
STUDY GOALS AND OBJECTIVES
REASONS FOR DOING THE STUDY
INTENDED AUDIENCE
SCOPE AND FORMAT
METHODOLOGIES AND INFORMATION SOURCES
ANALYST'S CREDENTIALS
RELATED BCC RESEARCH REPORTS
BCC RESEARCH WEBSITE
DISCLAIMER
CHAPTER 2 EXECUTIVE SUMMARY
EXECUTIVE SUMMARY
SUMMARY TABLE GLOBAL CATALYST AND CATALYST REGENERATION MARKETS, THROUGH 2019 ($ MILLIONS)
SUMMARY FIGURE GLOBAL CATALYST AND CATALYST REGENERATION MARKETS, 2011-2019 ($ MILLIONS)
CHAPTER 3 CATALYSTS AND CATALYST MARKETS
TABLE 1 IMPORTANT CATALYTIC PROCESSES DEVELOPED SINCE 1940
TYPES OF CATALYSTS
FIGURE 1 GLOBAL CATALYST MARKET SHARES BY TECHNOLOGY, 2014 (%)
SOLID CATALYSTS
TABLE 2 EXAMPLES OF SOLID CATALYSTS BY TYPE
TABLE 3 IMPORTANT PROPERTIES FOR SUPPORTS
TABLE 4 SPECIFIC SURFACE AREA FOR VARIOUS SUPPORTS
FIGURE 2 VARIOUS CATALYST SHAPES
TABLE 5 CATALYST MANUFACTURING PROCESSES
CATALYST APPLICATION MARKETS
FIGURE 3 GLOBAL CATALYST MARKET SHARES BY SEGMENT, 2014 (%)
FIGURE 4 GLOBAL CATALYST MARKET GROWTH PROJECTION BY SEGMENTS, 2011-2017 ($ BILLIONS)
FIGURE 5 GLOBAL CATALYST MARKET: ATTRACTIVENESS BY SEGMENT
TABLE 6 CATALYST MATERIAL AND APPLICATION MARKETS SUMMARY
ENVIRONMENTAL CATALYSTS MARKET
Automotive Emission Catalysts: Platinum, Palladium, Rhodium
FIGURE 6 LIGHT VEHICLE PRODUCTION TRENDS, 2013-2020 (MILLION UNITS)
FIGURE 7 HEAVY-DUTY VEHICLE PRODUCTION TRENDS, 2013-2020
(THOUSAND UNITS)
FIGURE 8 FUEL EMISSIONS REGULATORY TRENDS BY COUNTRY, 2010-2020
FIGURE 9 GASOLINE ENGINE, REGULATORY CONTROLS, TRENDS
FIGURE 10 DIESEL ENGINE, REGULATORY CONTROLS AND TRENDS
Platinum Group Metals Market and Its Influence
TABLE 7 PLATINUM GROUP METALS: CATALYST APPLICATIONS
TABLE 8 GLOBAL PGM DEMAND FOR AUTOMOTIVE CATALYSTS, THROUGH 2019 (THOUSAND OZ)
TABLE 9 GLOBAL PLATINUM DEMAND WITHIN THE AUTOCATALYTIC MARKET BY REGION, THROUGH 2019 (DATA IN THOUSAND OZ)
FIGURE 11 DISTRIBUTION OF PLATINUM DEMAND WITHIN THE AUTOMOTIVE CATALYST MARKET BY REGION, 2013 (%)
Palladium Market for Autocatalysts
TABLE 10 GLOBAL PALLADIUM DEMAND WITHIN THE AUTOCATALYTIC MARKET BY REGION, THROUGH 2019 (DATA IN THOUSAND OZ.)
FIGURE 12 DISTRIBUTION OF PALLADIUM DEMAND WITHIN THE AUTOMOTIVE CATALYST MARKET BY REGION, 2013 (%)
FIGURE 13 FLEET AVERAGE WEIGHT AND CO2 EMISSIONS BY CAR
MAKER AND EU TARGETS FOR 2020
TABLE 11 LIST OF COMPANIES IN THE EMISSION CONTROL MARKET
FOR AUTOMOBILES
NOx Reduction Catalysts
FIGURE 14 NOX REDUCTION CATALYSTS FOR MOBILE AND FIXED
SOURCES
Fuels: Sulfur Content Control
FIGURE 15 SULFUR CONTENT IN CRUDE FROM VARIOUS GLOBAL
LOCATIONS
FIGURE 16 SULFUR STANDARDS WORLDWIDE BY REGION, 2015 (PPM)
TABLE 12 REGIONAL GASOLINE SULFUR CONTENT REQUIREMENTS, 2012-2020
FIGURE 17 GLOBAL SULFUR STANDARDS FOR FUELS, 2012-2025 (PPM)
FIGURE 18 DESULFURIZATION CAPACITY ADDITIONS AND PROJECTIONS, 2012-2035 (MILLION BARRELS/DAY)
Bunker Fuel
FIGURE 19 WORLD FUEL OIL MARKETS: INLAND AND BUNKER, 2000-2020
FIGURE 20 IMO TIMELINE FOR SULFUR CONTENT REDUCTIONS, 2008-2025
Not All Sulfur is the Same
TABLE 13 SULFUR CONTENT IN VARIOUS FUELS AND THEIR
CHEMISTRY
Options for Desulfurization
Odor Removal Technologies
FIGURE 21 DEODORIZATION BY HONEYCOMB CATALYSTS
REFINING: THE CATALYST MARKET
FIGURE 22 PROVEN OIL RESERVES BY COUNTRY, 2014 (MILLION BARRELS)
FIGURE 23 OIL PRODUCTION BY COUNTRY, 2013 ('000 BARRELS OF OIL PER DAY)
FIGURE 24 TOP PETROLEUM COMPANIES BY CRUDE OIL PRODUCTION,2012 (‘000 BARRELS PER DAY)
FIGURE 25 PROVEN NATURAL GAS RESERVES BY COUNTRY, 2014 (TRILLION CUBIC FEET)
FIGURE 26 NATURAL GAS PRODUCTION BY COUNTRY, 2013 (BILLION CUBIC FEET)
FIGURE 27 TOP COMPANIES FOR NATURAL GAS PRODUCTION, 2012 (MILLION CUBIC FEET/DAY)
FIGURE 28 TOP PETROLEUM COMPANIES BY REVENUE, 2012 ($ ILLIONS)
Catalysts in the Refining Industry
FIGURE 29 SCHEMATIC OF A TYPICAL REFINERY OPERATIONS
FIGURE 30 GLOBAL REFINERY CATALYST MARKET SHARES BY SUBSEGMENT, 2013 (%)
FIGURE 31 REFINERY CATALYST MARKET GROWTH PROJECTION BY SUBSEGMENT, 2013 AND 2019 ($ BILLIONS)
FIGURE 32 GLOBAL REFINERY CATALYST MARKET SHARES BY REGION, 2012 (%)
Competitive Landscape for Hydroprocessing Catalysts
FIGURE 33 GLOBAL HYDROPROCESSING CATALYST MARKET
STRUCTURE CHANGE, 1985 VS. 2012 (%)
Shale Gas: How the Boom Affects the Catalyst Industry
FIGURE 34 GLOBAL SHALE GAS PRODUCTION BY REGION, 1990-2035 (BCF/D, %)
FIGURE 35 UNITED STATES NATURAL GAS PRODUCTION BY SOURCE, 1990-2040 (TRILLION CUBIC FEET/%)
POLYMER CATALYSTS MARKET
FIGURE 36 GLOBAL POLYMER CATALYST MARKET SHARES BY SUBSEGMENT, 2013 (%)
FIGURE 37 POLYMER CATALYST MARKET GROWTH PROJECTION BY SUBSEGMENT, 2013 AND 2019 ($ MILLIONS)
TABLE 14 MULTIPLE GENERATIONS OF PP ZN CATALYSTS
FIGURE 38 POLYPROPYLENE ZIEGLER-NATTA CATALYST MARKET SHARES
BY COMPANY, 2013 (%)
FIGURE 39 LINEAR POLYETHYLENE CATALYSTS MARKET SHARES BY COMPANY, 2013 (%)
CHEMICAL CATALYSTS MARKET
TABLE 15 GLOBAL CHEMICAL CATALYST MARKET, 2011 ($ MILLIONS)
TABLE 16 SKILL SETS REQUIRED FOR CATALYST TECHNOLOGY
DEVELOPMENT
GLOBAL CATALYSIS MARKET TRENDS
TREND 1: TOWARD HIGHER ACTIVITY AND SELECTIVITY OF CATALYSTS
FIGURE 40 TRENDS IN CATALYST DEVELOPMENT IN HYDROCRACKING
TABLE 17 CHANGE IN HYDROCRACKING OVER THE LAST 50 YEARS
TREND 2: CHANGES IN FEEDSTOCK AND MORE EFFICIENT USE OF FEEDSTOCK
Heavy Crudes Market
Technological Challenges
TABLE 18 GASIFICATION POTENTIAL FOR VARIOUS FUELS (%)
TREND 3: LOWER OPERATING TEMPERATURES
TREND 4: ENERGY EFFICIENCY
TREND 5: CREATING PROCESSES AROUND CATALYST TECHNOLOGIES
TREND 6: COAL IN CHINA
FIGURE 41 MARKET DRIVERS FOR COAL-BASED PROCESSES IN CHINA
TREND 7: GTL AS EMERGING TECHNOLOGY
FIGURE 42 CHEMICALS AND INDUSTRIES SUPPORTED BY NATURAL GAS
FIGURE 43 COST CURVE FOR NEW GTL PLANT INSTALLATIONS
TREND 8: OLEFINS MARKET GROWTH
TABLE 19 LARGEST ETHYLENE STEAM CRACKING PRODUCTION PLANTS WORLDWIDE AS OF JAN. 1, 2013
FIGURE 44 PROPYLENE DEMAND AND SUPPLY, 2001-2021
FIGURE 45 PROPYLENE YIELDS FROM VARIOUS PRODUCTION PROCESSES
FIGURE 46 PROPYLENE END-USE MARKETS: HISTORIC CHANGES, 1970 VS. 2004 (%)
FIGURE 47 POLYOLEFINS PRODUCTION CAPACITIES OF TOP PLAYERS, 2013
FIGURE 48 GLOBAL POLYOLEFIN MARKET BY REGION, 2005-2020 (MILLION MT/YR.)
INDUSTRY ORGANIZATIONS
CATALYST INDUSTRY IN NORTH AMERICA
FIGURE 49 U.S. CATALYST IMPORTS BY TYPE, 2010-2013 ($ ILLIONS)
TABLE 20 U.S. CATALYST IMPORTS BY TYPE AND COUNTRY, 2013 ($ MILLIONS)
FIGURE 50 U.S. CATALYST EXPORTS BY TYPE, 2010-2013 ($ ILLIONS)
TABLE 21 U.S. CATALYST EXPORTS BY TYPE AND STATE OF ORIGIN, 013 ($
MILLIONS)
TABLE 22 U.S. CATALYST EXPORTS BY TYPE AND COUNTRY, 2013 ($ MILLIONS)
CATALYST INDUSTRY IN EUROPE
TABLE 23 MEMBER COMPANIES OF EUROPEAN CATALYST MANUFACTURERS
ASSOCIATION
FIGURE 51 EUROPEAN CATALYST IMPORTS BY TYPE, 2010-2013 (MILLION EUROS)
TABLE 24 EUROPEAN CATALYST IMPORTS BY TYPE, 2010-2013 (MILLION
EUROS AND THOUSAND MTS)
FIGURE 52 EUROPEAN CATALYST EXPORTS BY TYPE, 2010-2013 (MILLION EUROS)
TABLE 25 EUROPEAN CATALYST EXPORTS BY TYPE, 2010-2013 (MILLION EUROS AND THOUSAND MTS)
TABLE 26 AVERAGE PRICES FOR CATALYSTS BY TYPE IN EUROPE, 2010-2013
($/KG)
FIGURE 53 AVERAGE PRICES FOR CATALYSTS BY TYPE IN EUROPE, 2010-2013 ($/KG)
FIGURE 54 NON-PGM CATALYST MARKET SHARES IN EUROPE BY METAL TYPE, 2012 (%)
CATALYST INDUSTRY IN JAPAN
TABLE 27 MEMBER COMPANIES OF CATALYST ASSOCIATION IN JAPAN
TABLE 28 AVERAGE PRICES FOR CATALYSTS BY SEGMENT, 2010-2013 ($/KG)
FIGURE 55 AVERAGE PRICES FOR CATALYSTS BY SEGMENT, 2010-2013 ($/KG)
FIGURE 56 JAPANESE CATALYST PRODUCTION BY MARKET SEGMENT,
2010-2013 (MT)
FIGURE 57 JAPANESE CATALYST MARKET BY SEGMENT, 2010-2013 (MILLION YEN)
FIGURE 58 JAPANESE CATALYST MARKET SHARES BY SEGMENT, 2013 (%)
GLOBAL CATALYST MARKET
TABLE 29 GLOBAL CATALYST TRADE EXPORTS BY COUNTRY, 2010-2012 ($ MILLIONS)
FIGURE 59 MARKET SHARES OF CATALYST EXPORTS BY COUNTRY, 2012 (%)
TABLE 30 GLOBAL CATALYST TRADE IMPORTS BY COUNTRY, 2010-2012 ($ MILLIONS)
FIGURE 60 MARKET SHARES OF CATALYST IMPORTS BY COUNTRY, 2012 (%)
CHAPTER 4 TECHNOLOGIES IN CATALYST REGENERATION
TECHNOLOGIES IN CATALYST REGENERATION
ALKYLATION OF LIGHT AROMATIC HYDROCARBONS
CATALYST USED
CATALYST ACTIVITY, PARTICLE SIZE AND PROCESS CHOICE
FIGURE 61 CATALYST ACTIVITY WITH PARTICLE SIZE AND PROCESS
DEACTIVATION OF THE CATALYST
REGENERATION METHODS
FIGURE 62 ESTIMATED GLOBAL LINEAR ALKYL BENZENE (LAB) DEMAND BY REGION/COUNTRY, 2015 (%)
ALKYLATION OF PARAFFINS AND OLEFINS
TABLE 31 LIST OF ALKYLATION REACTIONS
CATALYST USED
TABLE 32 LIST OF SULFURIC ACID REGENERATION FACILITIES
FIGURE 63 COMPARISON OF EFFICIENCIES OF SOLID-STATE CATALYSTS
USED IN ALKYLATION REACTIONS
DEACTIVATION OF THE CATALYST
REGENERATION METHODS
Chlorided Alumina
Hydrogen Fluoride
Sulfone + Hydrogen Halide + Water
CAPROLACTAM PRODUCTION
CATALYST USED
DEACTIVATION OF THE CATALYST
REGENERATION METHODS
CYCLIC ALDOL CONDENSATION
CATALYST USED
DEACTIVATION OF THE CATALYST
REGENERATION METHODS
DEHYDROGENATION
TABLE 33 DEHYDROGENATION PROCESSES IN COMMERCIAL OPERATION
CATALYST USED
DEACTIVATION OF THE CATALYST
REGENERATION METHODS
TABLE 34 COMPARISON OF ISOBUTANE DEHYDROGENATION
PROCESSES
FIGURE 64 COMPARISON OF ISOBUTANE DEHYDROGENATION
PROCESSES
DENITRIFICATION (EXHAUST GAS PURIFICATION)
TABLE 35 EMISSIONS FROM VARIOUS FOSSIL FUELS (G/KWH)
TABLE 36 PROPERTIES OF ORIMULSION COMPARED WITH ORINOCO OIL AND FUEL OIL C
CATALYST USED
DEACTIVATION OF THE CATALYST
FIGURE 65 PROCESS CONDITIONS FOR AMMONIUM SULFATE AND HYDROSULFATE FORMATION AND DEPOSITION ON SCR CATALYSTS
REGENERATION METHODS
FIGURE 66 GLOBAL GROWTH ESTIMATE FOR DIESEL EXHAUST FLUID, 2010-2020
FISCHER-TROPSCH PROCESS
FISCHER-TROPSCH PROCESS CONDITIONS
TABLE 37 FISCHER-TROPSCH PROCESS CONDITIONS, CATALYSTS AND REGENERATION TECHNIQUES
TABLE 38 COMPATIBILITY AND COMPARISON OF REFINING
TECHNOLOGIES WITH FISCHER-TROPSCH PROCESS
CATALYSTS USED
DEACTIVATION OF THE CATALYST
REGENERATION METHODS
FLUID CATALYTIC CRACKING
FIGURE 67 FCC SCHEMATIC
CATALYST USED
DEACTIVATION OF THE CATALYST
REGENERATION METHODS
Full Conversion of CO to CO2
TABLE 39 GUIDE FOR THE AMOUNT OF MANGANESE AND ANTIMONY TO BE USED IN THE CATALYST FOR FCC REACTIONS
Removal of Nitrogen Oxides
Removal of Sulfur
FCC ALLIANCE
FLUORINATION
TABLE 40 LIST OF FLUORINATION REACTIONS
TABLE 41 UNIQUE PROPERTIES OF ORGANIC FLUORINE COMPOUNDS AND APPLICATION MARKETS
TABLE 42 FLUORINE CHEMICALS AND MARKET APPLICATIONS
CATALYST USED
DEACTIVATION OF THE CATALYST
REGENERATION METHODS
FRIEDEL-CRAFTS REACTION
CATALYST USED
TABLE 43 COMPARISON OF ANISOLE CONVERSION BY FRIEDEL-CRAFTS REACTION UNDER 12 DIFFERENT CATALYSIS CONDITIONS
TABLE 44 COMPARISON OF FRIEDEL-CRAFTS CONVERSION OF ANISOLE WITH CARBOXYLIC ACIDS WITH MULTIPLE CATALYSTS
Ionic Liquids
DEACTIVATION OF THE CATALYST
Ionic Liquids
REGENERATION METHODS
Ionic Liquids
TABLE 45 IONIC LIQUID CATALYST REUSABILITY FOR THE FRIEDEL-CRAFTS REACTION OF PHENOL
FUEL CELL REACTIONS (PEM)
CATALYST USED
DEACTIVATION OF THE CATALYST
REGENERATION METHODS
GLYCOL PRODUCTION
CATALYST USED
DEACTIVATION OF THE CATALYST
REGENERATION METHODS
HYDROCARBON CONVERSION WITH IRIDIUM CATALYST
CATALYST USED
DEACTIVATION OF THE CATALYST
REGENERATION METHODS
HYDROCARBON CRACKING WITH A MIX OF ISOMERIZATION AND METATHESIS
CATALYSTS
CATALYST USED
METATHESIS CATALYSTS: NOBEL PRIZE-WINNING CHEMISTRY
DEACTIVATION OF THE CATALYST
REGENERATION METHODS
KOCH PROCESS
CATALYST USED
DEACTIVATION OF THE CATALYST
REGENERATION METHODS
METHANOL PRODUCTION
CATALYST USED
DEACTIVATION OF THE CATALYST
REGENERATION METHODS
MOTOR VEHICLE EXHAUST PURIFICATION
CATALYST USED
DEACTIVATION OF THE CATALYST
REGENERATION METHODS
OLEFIN EPOXIDATION
CATALYST USED
DEACTIVATION OF THE CATALYST
REGENERATION METHODS
TABLE 46 REACTIVITY OF CATALYST USED IN OLEFIN EPOXIDATION
UNDER VARIOUS REGENERATION CONDITIONS
OLIGOMERIZATION OF LOWER OLEFINS WITH SPA CATALYST
CATALYST USED
DEACTIVATION OF THE CATALYST
REGENERATION METHODS
OLIGOMERIZATION OF LOWER OLEFINS WITH ZEOLITE CATALYST
CATALYST USED
DEACTIVATION OF THE CATALYST
REGENERATION METHODS
TABLE 47 ILLUSTRATIVE STEPS FOR A SEQUENTIAL REACTOR ROTATION
TO OPTIMALLY USE ZEOLITE CATALYST IN OLEFIN OLIGOMERIZATION
OXYGEN REMOVAL
CATALYST USED
DEACTIVATION OF THE CATALYST
REGENERATION METHODS
CHAPTER 5 CATALYST REGENERATION PROCESSES
CATALYST REGENERATION: WHY AND HOW
DEFINING END OF PROCESSING CYCLE
CONTAMINATIONS/POISONS
TABLE 48 PROCESSES, CATALYSTS AND POISONS
Case 1-Partial Batch Savings by Bin Analysis
FIGURE 68 ANALYSIS OF UNLOADED CATALYST FOR REGENERATION DECISION, CASE 1
Case 2-Partial Batch Savings by Bin Analysis
FIGURE 69 ANALYSIS OF UNLOADED CATALYST FOR REGENERATION DECISION, CASE 2
Case 3-Analysis Also Providing Carbon Profiling within the Reactor
FIGURE 70 ANALYSIS OF CATALYST FOR CARBON PROFILING OF THE REACTOR, CASE 3
Case 4-Catalyst Regeneration Not Recommended
FIGURE 71 ANALYSIS OF CATALYST CONFIRMING REGENERATION AS NOT POSSIBLE, CASE 4
NATURE AND CHEMISTRY OF COKE DEPOSITS ON THE CATALYST
TABLE 49 COKE DEPOSIT CONSTITUENTS
TESTS FOR CONFIRMING CATALYST REGENERATION AS SUCCESSFUL
TABLE 50 PROPERTY TARGETS FOR REGENERATED CATALYSTS
MONITORING OF CATALYST REGENERATION
FIGURE 72 CATALYST REGENERATION MONITORING BY MASS
SPECTROSCOPY
HYDROTREATING CATALYST REGENERATION
TABLE 51 HYDROTREATING CATALYSTS AND MANUFACTURERS
TABLE 52 REGENERATION OF HYDROTREATING CATALYST
AUTOMOTIVE EMISSION CATALYSTS AND REGENERATION
TABLE 53 COMPONENTS OF EXHAUST FROM GASOLINE AND DIESEL
ENGINES
FIGURE 73 OPERATIONAL WINDOW FOR A THREE-WAY CATALYST
FIGURE 74 OXYGEN SENSOR DATA FROM A THREE-WAY CATALYST IN OPERATION
FIGURE 75 REGENERATION MONITORING FOR A PT-BAO-AL2O3
CATALYST
Deactivation
Passive Regeneration
Active Regeneration
REGENERATION OF RH/PT CATALYST FOR E85 REFINING
FIGURE 76 CATALYST REGENERATION OF RHODIUM/PLATINUM
CATALYST USED FOR E-85 REFORMING
INDUSTRIAL EMISSIONS AND CONTROL
TABLE 54 INDUSTRIAL PROCESSES AND EMISSIONS
DENOX TECHNOLOGIES: SCR
FIGURE 77 SCHEMATIC OF A TYPICAL SCR REACTOR
SCR CATALYST REGENERATION: COST ANALYSIS
TABLE 55 FINANCIAL ANALYSIS FOR CATALYST REGENERATION: SCR
UNIT
SCR CATALYST MANAGEMENT
FIGURE 78 CATALYST MANAGEMENT PLAN FOR AN SCR REACTOR
EFFECT OF CARRIERS ON REGENERATION
TABLE 56 ALUMINA SUPPORT PHASE TRANSFORMATIONS
TABLE 57 ZEOLITE CARRIERS USED IN CATALYSIS
USAGE OF REGENERATED CATALYST
TABLE 58 USES OF REGENERATED CATALYSTS BY APPLICATION
CATALYST RECOVERY
TABLE 59 COMPARISON OF METAL RECOVERY BY VARIOUS LEACHING
AND ROASTING METHODS
CHAPTER 6 CATALYST REGENERATION MARKET
FIGURE 79 BUSINESS MODEL OF CATALYST MANUFACTURERS: INTEGRATED
PLAYERS
FIGURE 80 BUSINESS MODEL OF CATALYST MANUFACTURERS: INDEPENDENT
PLAYERS
HISTORY OF THE CATALYST REGENERATION MARKETPLACE
CATALYST MARKET
TABLE 60 GLOBAL CATALYST MARKET, THROUGH 2019 ($ MILLIONS)
FIGURE 81 GLOBAL CATALYST MARKET, 2011-2019 ($ MILLIONS)
CATALYST REGENERATION MARKET
TABLE 61 GLOBAL CATALYST REGENERATION MARKET, THROUGH 2019 ($ MILLIONS)
FIGURE 82 GLOBAL CATALYST REGENERATION MARKET, 2011-2019 ($ MILLIONS)
TABLE 62 SHARES OF FRESH AND REGENERATED CATALYSTS IN THE GLOBAL CATALYST MARKET, 2011-2019 (%)
FIGURE 83 SHARES OF FRESH AND REGENERATED CATALYSTS IN THE GLOBAL CATALYST MARKET, 2011-2019 (%)
OFF-SITE AND ON-SITE REGENERATION
TABLE 63 ON-SITE AND OFF-SITE CATALYST REGENERATION, THROUGH 2019 ($ MILLIONS)
FIGURE 84 ON-SITE AND OFF-SITE CATALYST REGENERATIONS, 2011-2019 ($ MILLIONS)
TABLE 64 ON-SITE AND OFF-SITE CATALYST REGENERATION, 2011-2019
(%)
MARKET SEGMENTS
ENVIRONMENTAL MARKET
REFINERY MARKET
TABLE 65 LARGEST REFINERIES IN THE WORLD
POLYMER MARKET
CHEMICAL MARKET
TABLE 66 CATALYST REGENERATION MARKET SHARES BY SEGMENT, 2013 (%)
FIGURE 85 CATALYST REGENERATION MARKET SHARES BY SEGMENT, 2013 (%)
TABLE 67 CATALYST REGENERATION MARKET BY SEGMENT, THROUGH 2019 ($ MILLIONS)
FIGURE 86 CATALYST REGENERATION MARKET BY SEGMENT, 2011-2019 ($ MILLIONS)
TABLE 68 CATALYST REGENERATION MARKET SHARES BY SEGMENT, 2011-2019 (%)
REGIONAL MARKETS
ENVIRONMENTAL MARKET BY REGION
TABLE 69 COMPARISON OF EMISSIONS FROM COAL AND NATURAL GAS
POWER PLANTS
Coal-Powered Utilities
TABLE 70 COAL POWER PLANTS WORLDWIDE BY COUNTRY, NUMBER OF PLANTS AND TOTAL CAPACITY, 2014
Oil-Powered Utilities
TABLE 71 OIL-POWERED PLANTS WORLDWIDE BY COUNTRY, NUMBER OF PLANTS AND TOTAL CAPACITY, 2014
Gas-Powered Utilities
TABLE 72 GAS-POWERED PLANTS WORLDWIDE BY COUNTRY, NUMBER OF PLANTS AND TOTAL CAPACITY, 2014
FIGURE 87 GLOBAL POTENTIAL SCR CATALYST MARKET SHARES BY REGION, 2014 (%)
REFINERY MARKET BY GEOGRAPHICAL REGION
FIGURE 88 GLOBAL DISTRIBUTION OF REFINING CAPACITY BY REGION, 2013 (%)
TABLE 73 GLOBAL REFINING CAPACITY BY REGION, THROUGH 2019 (MILLION BARRELS/DAY)
FIGURE 89 GLOBAL CATALYST REGENERATION MARKET SHARES BY REGION, 2013 (%)
COMPANIES ACTIVE IN CATALYST REGENERATION
TABLE 74 COMPANIES ACTIVE IN CATALYST REGENERATION
GLOBAL CAPACITY FOR CATALYST REGENERATION
TABLE 75 GLOBAL CATALYST REGENERATION CAPACITY, THROUGH 2019 (MT)
FIGURE 90 GLOBAL CATALYST REGENERATION CAPACITY, 2011-2019 MT)
CHAPTER 7 REGULATIONS
INTRODUCTION
INFORMATION SOURCES
TABLE 76 INFORMATION SOURCES FOR REGULATIONS AND POLICIES
AFFECTING THE CATALYST REGENERATION INDUSTRY
U.S. FEDERAL REGULATIONS FOR AIR POLLUTION CONTROLS
ENVIRONMENTAL PROTECTION AGENCY (EPA)
Catalyst Recycling and Regeneration and CDR Reporting
Scenario 1
Clarification Provided by EPA
Scenario 2
Clarification Provided by EPA
MERCURY EMISSION REGULATIONS
RICE-NESHAP REGULATIONS
Spark-Ignited Engines
Diesel Compression-Ignited Engines
REACH: REGULATIONS IN EUROPE
TABLE 77 HISTORY OF REGISTRATION REQUIREMENTS UNDER REACH
TABLE 78 CHEMICALS REGISTERED UNDER REACH BY EURECAT AND TRICAT
REGULATIONS IN CHINA
TWO-WHEELER REGULATIONS BY COUNTRY
TABLE 79 TWO-WHEELER EMISSION REGULATIONS BY COUNTRY
TABLE 80 COMPANIES ACTIVE IN ORGANIZATIONS RELATED TO EMISSION
CONTROLS IN VARIOUS REGIONAL MARKETS
TRANSBOUNDARY MOVEMENT OF WASTE
CHAPTER 8 PATENT ANALYSIS
PATENT ANALYSIS
FIGURE 91 NUMBER OF U.S. PATENTS ISSUED ON CATALYST REGENERATION TECHNOLOGIES SINCE 1976*
PATENT ANALYSIS BY YEAR
FIGURE 92 NUMBER OF U.S. PATENTS ISSUED ON CATALYST REGENERATION TECHNOLOGIES SINCE 1976 BY YEAR, FIRST METHOD*
FIGURE 93 NUMBER OF U.S. PATENTS ISSUED ON CATALYST REGENERATION TECHNOLOGIES SINCE 1976 BY YEAR, SECOND METHOD*
CORE PATENTS IN CATALYST REGENERATION TECHNOLOGY
TABLE 81 U.S. PATENTS SPECIFIC TO CATALYST REGENERATION TECHNOLOGIES, 1976 TO APRIL 2015
PATENT ANALYSIS BY COMPANY
TABLE 82 NUMBER OF U.S. CATALYST REGENERATION PATENTS BY COMPANY
FIGURE 94 COMPANY MARKET SHARES OF U.S. PATENTS ISSUED ON CATALYST REGENERATION (%)
PATENT ANALYSIS BY TECHNOLOGY
PATENT ANALYSIS BY CATALYST USED
TABLE 83 NUMBER OF U.S. PATENTS BY CATALYST TYPE AND ASSIGNEE
COMPANIES FOR CATALYST REGENERATION TECHNOLOGIES
MONOPOLIES FOR TECHNOLOGIES
PATENT ANALYSIS BY CARRIERS USED
TABLE 84 CATALYSTS MENTIONED IN PATENTS BY CARRIER TYPE
TECHNOLOGICAL ANALYSIS AND UNEXPLORED AREAS
UNEXPLORED AREA 1
TABLE 85 LIST OF COUNTRIES WITH CATALYST IMPORTS EXCEEDING $50 MILLION, 2012 ($ MILLIONS)
UNEXPLORED AREA 2
CHAPTER 9 COMPANY PROFILES
TABLE 86 MAJOR COMPANIES IN THE GLOBAL CATALYST MARKETPLACE
ACCELRYS INC.
ADVANCED CATALYST SYSTEMS LLC
PRODUCTS
LICENSES AND TECHNOLOGIES
REGENERATION AND RECYCLING
ADVANCED METALLURGIC GROUP NV
AMG VANADIUM
FIGURE 95 SPENT CATALYST RECYCLING CAPACITY AT AMG, 2000-2014 (MT)
AL BILAD CATALYST CO. LTD. (ABC)
TABLE 87 LIST OF AL BILAD CUSTOMERS WORLDWIDE BY COUNTRY
ALBEMARLE CORP.
CATALYST PRODUCTS
TOTAL CATALYST MANAGEMENT
REACT TECHNOLOGY
HYDROPROCESSING CATALYSTS
SULFICAT: TOTSUCAT STAX TECHNOLOGIES
FLUID CATALYTIC CRACKING CATALYSTS
ALKYCLEAN TECHNOLOGY
CUSTOMERS
COMPETITORS
LOCATIONS OF CATALYST REGENERATION
PARTNERSHIPS AND JOINT VENTURES
TABLE 88 ALBEMARLE: PARTNERSHIPS AND JOINT VENTURES SUMMARY
FINANCIALS
FIGURE 96 ALBEMARLE REVENUES FROM CATALYST SEGMENT, 2009-2013 ($ MILLIONS)
ARISTO INTELLIGENT CATALYST TECHNOLOGY
AXENS
TABLE 89 AXENS: LIST OF CATALYSTS BY INDUSTRY AND APPLICATION BABCOCK HITACHI KK (NOW MITSUBISHI HITACHI POWER SYSTEMS LTD.)
AKITSU WORKS
CHINA CATALYST WORKS
SERVICES
BABCOCK POWER INC.
BASF
LOCATIONS
SEGMENTS, MARKET POSITION AND COMPETITORS
Mobile Emissions Catalysts
Process Catalysts and Technologies
Battery Materials
Precious and Base Metal Services
RECENT DEVELOPMENTS
Mobile Emissions Catalysts
Process Catalysts
Material Services
FINANCES
FIGURE 97 BASF REVENUES FROM CATALYST SUBSEGMENTS, 2009-2013 (MILLION EUROS)
FIGURE 98 DISTRIBUTION OF BASF CATALYST REVENUES BY REGION, 2013 (%)
FIGURE 99 BASF CATALYST REVENUE SHARES BY MARKET, 2013 (%)
BAYER TECHNOLOGY SERVICES GMBH
CASE STUDY: IN SITU CATALYST REGENERATION MONITORING
FIGURE 100 EXAMPLE OF IN SITU MONITORING OF CATALYST
REGENERATION FOR PROCESS CONTROL
FIGURE 101 EXAMPLE OF HYDROGENATION MONITORING USING IR
SPECTROSCOPY
GREEN MATTER: A DREAM REACTION
BERGARI SOLUTIONS LLC
CATALYTIC COMBUSTION CORP.
CDTI
MIXED-PHASE CATALYST (MPC) TECHNOLOGY
ZPGM: A DISRUPTIVE TECHNOLOGY
TABLE 90 HONDA VEHICLE PLATFORMS WITH CDTI TECHNOLOGIES
CELANESE
CATALYST REGENERATION
TABLE 91 U.S. PATENTS ASSIGNED TO CELANESE RELATED TO CATALYSTS AND REGENERATION
CHEMTRADE
SULFURIC ACID REGENERATION
CHEVRON LUMMUS GLOBAL
TABLE 92 TECHNOLOGY INNOVATIONS AT CHEVRON LUMMUS SINCE 1959
ISOCRACKING TECHNOLOGY
ISODEWAXING TECHNOLOGY
MERCAWAY TECHNOLOGY
ZEOLITEPLUS TECHNOLOGY
CUSTOMERS
TABLE 93 LIST OF CUSTOMER UNITS RUNNING LC-FINING TECHNOLOGY
RECENT DEVELOPMENTS
CHROMALOX
CLARIANT INTERNATIONAL
TABLE 94 CLARIANT COMPANY FINANCIALS, CATALYST SEGMENT AND SUBSIDIARIES (MILLIONS CHF*)
RECENT DEVELOPMENTS
PRODUCTS
PRODUCTS BY MARKET SEGMENTS
TABLE 95 CLARIANT CATALYST PORTFOLIO
REGENERATION
CLEAN HARBORS
COALOGIX (SCR-TECH LLC)
REGULATIONS: A DRIVER FOR COMPANY GROWTH
OPERATIONS
OWNERSHIP HISTORY
MARKET AND CUSTOMERS
CORMETECH INC.
LOCATIONS
TECHNOLOGY AND PRODUCTS
CUSTOMERS
FIGURE 102 DISTRIBUTION OF CORMETECH SCR SYSTEM INSTALLATIONS BY INDUSTRY SEGMENT (%)
NEW DEVELOPMENTS
CRI CATALYST COMPANY LTD. (CRITERION)
CRITERION CATALYSTS AND TECHNOLOGIES LP
TECHNOLOGY LICENSING
CATALYSTS
REGENERATION ACTIVITIES
DCL AMERICA INC.
DONGFANG ELECTRIC CORP. LTD.
DOW OIL AND GAS
CATALYSTS AND REGENERATION
DUPONT
ALKYLATION TECHNOLOGY (STRATCO)
SULFURIC ACID TECHNOLOGIES
ORGANIZATION
MECS Inc.
Belco Technologies
IsoTherming
EBINGER KATALYSATOR SERVICE GMBH & CO. KG
SONOCHEMICAL CLEANING: A PATENTED TECHNOLOGY
CUSTOMERS
TABLE 96 LIST OF CUSTOMERS AND CATALYSTS REGENERATED BY EBINGER
ECO-RIGEN S.R.L
REGENERATION PROCESS
TOTSUCAT: SULFIDING
ENVIRONEX INC.
CUSTOMERS
TABLE 97 LIST OF CUSTOMER OF ENVIRONEX
ENVIRONMENTAL SOLUTIONS WORLDWIDE INC. (ESW GROUP)
PRODUCTS
COMPETITORS
ENVIROTHERM GMBH (FORMER KWH)
COMPANY STRUCTURE
COLLABORATIONS AND LICENSES
PRODUCTS
SERVICES
CUSTOMER INDUSTRIES
TABLE 98 LIST OF CUSTOMERS OF ENVIROTHERM
ERAMET GROUP
EURECAT SA
ORGANIZATION
FIGURE 103 EURECAT COMPANY ORGANIZATIONAL STRUCTURE
Eurecat SA
Eurecat France
Eurecat U.S. Inc.
Eurecat U.S. Inc. (regeneration unit)
AlBilad Catalyst Co. Ltd.
Eco-Rigen S.r.l.
Petroval
Tricat GmbH
Eurecat India Catalyst Services Pvt. Ltd.
Eurecat Singapore
Nippon Eurecat
L.E. Ufaneftekhim Refinery
COMPANY HISTORY
RECENT DEVELOPMENTS
SERVICES AND TECHNOLOGIES
Regeneration of Catalysts
FIGURE 104 ROTO LOUVRE USED BY EURECAT FOR CATALYST
REGENERATION
Presulfiding
FIGURE 105 COMPARISON OF OFF-SITE AND ON-SITE SULFIDATION
PROCESSES
Preconditioning
Technology Licenses
Reclamation
EURO SUPPORT B.V.
ASM CATALYSTS LLC
EUROMET
CATALYST RECYCLING: CATEAM
EVONIK INDUSTRIES AG
TABLE 99 LIST OF CATALYSTS OFFERED BY EVONIK
BIOFUELS AS GROWTH AREA
ORGANOMETALLIC TIN CATALYSTS
FUEL TECH INC.
FULL YIELD INDUSTRY CO. LTD. (FYI)
LONDON CHEMICALS & RESOURCES LTD.
GENERAL CHEMICAL CORP. (GENCHEM)
GULF CHEMICAL & METALLURGICAL CORP. (GCMC)
HALDOR TOPSOE A/S
SEGMENTS AND ACTIVITIES
PRODUCTS AND SERVICES
TECHNOLOGIES AND LICENSES
HEADWATERS TECHNOLOGY INNOVATION (HTI)
COMPANY HISTORY
TECHNOLOGIES DEVELOPED
HCAT and DCL Technologies
HERAEUS PRECIOUS METALS
CATALYSTS
CATALYST REFINING AND RECYCLING
HITACHI ZOSEN CORP.
HITACHI ZOSEN CATALYST
HUNTSMAN CORP
AMINES
IDEMITSU KOSAN CO. LTD.
IFP ENERGIES NOUVELLES
TABLE 100 IFP: PORTFOLIO OF INDUSTRIAL INVESTMENTS
TABLE 101 LIST OF COMPANIES THAT COLLABORATE WITH IFP
CATALYST RESEARCH ACTIVITIES
AXENS
EURECAT
INTERTEK
INTERTEK AMERICAS
Services
Intertek Pilot Plant Services
JEANBLANC INTERNATIONAL
JGC CATALYSTS AND CHEMICALS LTD. (JGC & CC)
CASE STUDY: DTP PROCESS FOR PROPYLENE PRODUCTION
TABLE 102 COMPARISON OF PROPYLENE PRODUCTION PROCESSES
FIGURE 106 CATALYST ACTIVITY THROUGH REGENERATION CYCLES
FOR PROPYLENE PRODUCTION BY DTP
JOHNSON MATTHEY
EMISSION CONTROL TECHNOLOGIES
PROCESS TECHNOLOGIES
TABLE 103 JOHNSON MATTHEY CATALYSTS AND PROCESSES
SUPPORTED
PRECIOUS METAL PRODUCTS/REFINING
FINE CHEMICALS
NEW BUSINESS
REGENERATION TECHNOLOGIES
FIGURE 107 ACTIVE DPF REGENERATION TECHNOLOGY-PROCESS
DETAILS
TABLE 104 DPF REGENERATION TECHNOLOGIES: A COMPARISON
PALLADIUM CATALYST SCAVENGING: THE SMOPEX FIBER FAMILY
RECENT DEVELOPMENTS
KAIDA CO.
PRODUCTS
TABLE 105 CATALYSTS FROM KAIDA SHOWING PGM LOADING LEVELS
BY APPLICATION
PGM RECOVERY
KBR
KC COTTRELL
KC ENVIRO SERVICES
KC CATALYST SERVICES
LIQTECH INTERNATIONAL A/S
LYONDELLBASELL
LYONDELLBASELL U.S.
TRANS4M S TECHNOLOGY
VACIDO TECHNOLOGY
METCHEM (METALCHEMIC RECYCLING) BV
MIRATECH CORP.
MITSUBISHI CHEMICAL CORP.
MITSUBISHI HEAVY INDUSTRIES
MITSUBISHI HITACHI POWER SYSTEMS AMERICA
MITSUI CHEMICALS INC.
LICENSING DIVISION
NEW TECHNOLOGY DEVELOPMENT
MOURIK INTERNATIONAL BV
MOXBA-METREX BV
SPENT CATALYST PROCESSING
N.E. CHEMCAT CORP.
NANO
NEW CHEMICAL SYNTHESES INSTITUTE
INORGANIC CHEMISTRY DIVISION (ICHN) GLIWICE
CATALYST PRODUCTS
CUSTOMERS
NIKKI-UNIVERSAL CO. LTD.
NIPPON KETJEN
NIPPON SHOKUBAI CO. LTD.
CATALYSTS
TABLE 106 NIPPON SHOBUKAI FINANCIALS FOR CATALYST SEGMENT,2011-2013 (MILLION YEN)
NOVA CHEMICALS
CATALYST TECHNOLOGIES
PEMEX
POROCEL
SERVICES AND TECHNOLOGIES
FIGURE 108 POROCEL'S MOVING BELT REGENERATION
PROCESS:SCHEMATIC
CATALYST TESTING
LICENSES
RECENT DEVELOPMENTS
TABLE 107 POROCEL DISTRIBUTION OF CATALYST REGENERATION BY TYPE OF CATALYST, 2014 (%)
FIGURE 109 POROCEL DISTRIBUTION OF CATALYST REGENERATION BY TYPE OF CATALYST, 2014 (%)
PQ CORP.
RENEWABLE ENERGY GROUP (REG)
SYNTROLEUM CORP.
TABLE 108 COMPARISON OF IRON AND COBALT CATALYSTS FOR THE FISCHER-TROPSCH PROCESS
DYNAMIC FUELS
SYNTROLEUM TECHNOLOGIES
Syntroleum Process
CTL Process
Synfining
Bio-Synfining
CUSTOMERS
CATALYST REGENERATION TECHNOLOGY
TABLE 109 U.S. PATENTS GRANTED TO SYNTROLEUM ON CATALYST
REGENERATION
REPSOL YPF
SAMSUNG ENGINEERING CO. LTD.
TABLE 110 SAMSUNG ENGINEERING PROJECTS RELATED TO CATALYST
MARKETS
SASOL
FIGURE 110 COMPARISON OF LAB SCALE AND COMMERCIAL SCALE
CATALYST REGENERATION TESTS AT SASOL
SHOWA SHELL SEKIYU KK
SINOPEC CATALYST CO. (SCC)
SINOPEC TECH
TABLE 111 TECHNOLOGIES LICENSED BY SINOPEC WITH CATALYST
REGENERATION
TABLE 112 SINOPEC CATALYSTS THAT CAN BE REGENERATED
SOLVAY SA
RHODIA SA
STEAG ENERGY SERVICES LLC
TAIYO KOKO CO.
PRODUCTS
TANAKA HOLDINGS CO., LTD
TABLE 113 CATALYST PRODUCTS FROM TANAKA
TORFTECH GROUP
TORFTECH (CANADA) INC.
CATALYST APPLICATIONS
TREIBACHER INDUSTRIE AG
TRICAT
IN SITU AND EX SITU REGENERATIONS COMPARED
RECENT DEVELOPMENTS
SERVICES AND TECHNOLOGIES
LICENSES FOR TECHNOLOGY
UMICORE
RECENT DEVELOPMENTS
FIGURE 111 UMICORE REVENUES FROM CATALYSIS SUBSEGMENT, 2009-2013 (MILLION EUROS)
UNIVATION TECHNOLOGIES
FIGURE 112 POLYETHYLENE PRODUCTION CAPACITY AND TECHNOLOGIES PROVIDED BY UNIVATION,1968-2010
UOP
CATALYSTS
ALBEMARLE ALLIANCE: HYDROTREATING
REGENERATION
CONTINUOUS CATALYST REGENERATION
FIGURE 113 DISTRIBUTION OF UOP CCR PLATFORMING UNITS BY REGION (% TOTAL OPERATING UNITS = 224)
CATALYST REGENERATION CONTROL SYSTEM
FINANCIALS
FIGURE 114 UOP COMPANY REVENUES, 2009-2013 ($ MILLIONS)
VELOCYS INC.
TABLE 114 LIST OF VELOCYS REACTORS WORLDWIDE
FIGURE 115 DISTRIBUTION OF GAS FIELDS BY SIZE
FIGURE 116 VELOCYS MICROCHANNEL REACTOR DESIGN SCHEMATIC
TABLE 115 COMPARISON OF HEAT AND MASS TRANSFER BY MICROCHANNEL TECHNOLOGY AND CONVENTIONAL
PROCESSES
FIGURE 117 VELOCYS IP PORTFOLIO SUMMARY
W.R. GRACE
CATALYST PRODUCTS
FINANCIALS
FIGURE 118 W.R. GRACE CATALYST SEGMENT FINANCIALS BY MARKETS, 2011-2013 ($ MILLIONS)
FIGURE 119 W.R. GRACE CATALYST SEGMENT FINANCIALS BY REGION, 2011-2013 ($ MILLIONS)
YARA INTERNATIONAL ASA
ZEOLYST INTERNATIONAL
ZIBO HENGJI CHEMICAL CO. LTD.
CATALYST REGENERATION

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