Refinery Catalysts : Market Leaders 2018-25 | Albemarle, BASF, Haldor Topsoe, Honeywell / UOP

Press Release - 09 Mar 2018

Global Research and Development News --
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Report Description-
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– Global Refinery Catalysts Market: Snapshot –
The global market for refinery catalysts is gaining high prominence owing to the important role played by refinery catalysts in the cracking process in petroleum refineries. While the massive global consumption of petroleum products, which continues to rise at a steady pace, is a key driver of the market, stringent government regulations pertaining to the emissions produced by vehicles and other industrial sectors are also expected to play a big role in the development of the market in the next few years.
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In the past 2-3 years, the massive volatility in crude oil prices on a global front has had a significant negative impact on the production volumes and revenues of several refinery catalyst manufacturers. Analysts suggest that the situation will remain unchanged or will modify at a very slow pace. It will be a while until the global costs of crude oil settle at a gainful margin and the scenario will lead to some challenges to the growth of the companies operating in the global refinery catalyst market.

Nevertheless, companies in the market could benefit from the thriving automotive and automotive fuels industries in Asia Pacific in the near future. Stringent regulations governing vehicle emissions in North America and Europe will also present the increased demand for refined oil, thus driving the demand for refinery catalysts in turn.

The study addresses hydroprocessing catalysts and FCC catalysts. Hydroprocessing catalysts are used to create cleaner fuels--especially ULSD. Demand for cleaner fuels is driving the market. Refining catalysts are experiencing strong growth. New fuel standards are coupled with refineries increasing use of heavier and dirtier feedstocks and major additions to refining capacity.

The refinery catalyst market is thus boosted by the fact that the efficient use of catalysts can help the manufacturers' better address the increasing energy demand. Fluid catalytic cracking (FCC) is the conversion process used in petroleum refineries. It is widely used to convert the high-boiling, high-molecular weight hydrocarbon fractions of petroleum crude oils to more valuable gasoline, olefinic gases and other products.

Cracking of petroleum hydrocarbons is done by catalytic cracking because it produces more gasoline with a higher-octane rating. Byproduct gases are more olefinic. These are more valuable than those produced by thermal cracking.

The feedstock to an FCC is that portion of the crude oil that has an initial boiling point of 340 °C or higher at atmospheric pressure. The average molecular weight ranges from about 200 to 600 or higher. This portion of crude oil is often referred to as heavy gas oil. The FCC process vaporizes and breaks the long-chain molecules of the high-boiling hydrocarbon liquids into much shorter molecules by contacting the feedstock, at high temperature and moderate pressure, with a fluidized powdered catalyst.

Hydroprocessing faces significant challenges as crude feeds get heavier; there will be more sulphur and nitrogen to extract; more aromatics to saturate; more metals to remove; and more coke to deal with. Refiners have ageing facilities, which may not be designed and optimized to meet new challenges. As more capital investment is needed, costs for refining fossil fuels will rise, stimulating markets for renewable energy, making them more competitive with fossil fuels.

The cost of hydrocracking catalysts varies because of composition differences. The catalysts can be alumina with base metals or contain added crystalline zeolites. High quality ultra-stable type Y molecular sieve zeolites are used in this service. Nickel-moly or nickel-tungsten are the active metals frequently used.

FCC additives are used with catalysts to meet specific unit objectives. Higher gasoline octane, lower gasoline sulfur, lower sulfur oxides (SOx) and nitrogen oxides emissions, lower carbon monoxide levels, improve fluidization, make more propylene and/or liquefied petroleum gas (LPG) and improve bottoms cracking are FCC objectives.

“Fluid Catalytic Cracking (FCC) petroleum refining products overcome limiting factors affecting refinery capacity and operating flexibility to deliver value and performance. Catalysts are a crucial component in the processing of highly valued petrochemicals, gasoline, diesel and other fuels.”

The market for refinery catalysts in the oil refining sector at $4,967 million in 2016 is expected to be worth $6,490 million by 2023, growing at 3.8% on average between 2017 and 2023. There are 500 FCC units being operated globally, each of which requires a constant supply of FCC catalysts. There are 3,000 HPC units being operated globally, or a capacity of approximately 44 million barrels per day, each of which typically requires replacement HPC catalysts once every one to four years.

– Companies Profiled –

Market Leaders
– Albemarle
– BASF
– Haldor Topsoe
– Honeywell / UOP
– Advanced Refining Technologies (ART)
– WR Grace
– Clariant AG / Süd-Chemie AG
– Shell CRI
– IFP Energies nouvelles Group Company / Axens
– Sinopec China Petrochemical Corporation
– Shell / Criterion

Market Participants
– Air Products
– Advanced Energy Materials LLC
– Chevron
– Clean Diesel Technologies
– Clean Diesel Technologies / Catalytic Solutions
– Dow
– Evonik Industries
– ExxonMobil Catalysts and Licensing LLC,
– Headwaters Technology Innovation (HTI)
– IFP Energies Nouvelles Group Company / Axens / Eurecat UNICAT Catalyst Technologies
– Indian Oil Corporation
– Johnson Matthey
– KBR Hydroprocessing
– Nanostellar
– Petrobras Partnership with Albemarle
– Quantiam Technologies Inc.
– Rive Technology and Grace Davison
– Shell
– Shell / Sekiyu
– Shoaibi Group / General Technology & Systems Company Ltd (GENTAS)
– UNICAT Catalyst Technologies
– Zeochem
– Zeolyst
– Selected Refinery Catalyst Companies
– Emerging Catalyst Companies
– FCC Catalyst & Additive Suppliers
– Government Agencies and Other Organizations

Key Topics
– Catalysts
– Petroleum Process
– Chemical Process
– Fluid Catalytic Cracking FCC Catalysts
– Hydroprocessing Catalysts
– Metal Refinery Catalys
– Nanotechnology
– Related Energy
– Depleting Crude Oil Reserves
– Process Catalysts
– Refining Catalysts
– Refining Industry
– Refining Capacity
– Maximizing Diesel Production
– Hydrocracking
– Hydrotreating
– Hydrotreating Process
– Distillate Hydrotreating
– Lithium Carbonate
– Lithium Chemicals
– Lithium Market Opportunity
– Rare Earth Minerals
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Table of Contents
Refinery Catalysts Executive Summary 41
Refinery Catalysts Market Driving Forces 41
Change Is the Only Constant 43
Shift In Refiners' Raw Material Consumption Toward Heavier Feedstocks 45
Lower Sulfur Specifications Worldwide 46
Refinery Catalysts Market Shares 46
Refinery Catalysts Market Forecast 2016 49
1. Refinery Catalysts Market Description And Market Dynamics 51
1.1 Fluid Catalytic Cracking FCC Catalysts And Hydroprocessing Catalysts 51
1.1.1 Reducing Emissions From Diesel Engines 53
1.1.2 On-Road Vehicles Emission Of Nitrogen Oxide 54
1.1.3 Fluid Catalytic Cracking (FCC) 54
1.2 Identifying Trends In The Refining Catalyst Market 55
1.2.1 Depleting Crude Oil Reserves 57
1.2.2 Catalysts Have To Be Protected From Particulates And Foulants 57
1.2.3 Conversion Rates 58
1.2.4 Catalyst Platforms Customized Solution For Each Specific Refinery Or Unit Operation 59
1.2.5 Residue Upgrading Challenge 59
1.3 Process Catalysts 59
1.4 Refining Catalysts 60
1.4.1 Refining Catalyst Economic Trends: Btu Growth In Energy Consumption 60
1.4.2 Refining Catalyst Business Trends 60
1.4.3 Refining Catalyst Business: Transformation From Regional To Global Undertaking, Leveraging Economies Of Scale 61
1.4.4 Increased Manufacturing Costs 61
1.4.5 Catalyst Customization 61
1.5 Market Changes Impacting Refineries 63
1.5.1 Refinery Catalysts 63
1.6 Refinery Catalysts: Suppliers Tap Emerging Markets 65
1.6.1 Refining Industry 66
1.7 Global Refining Industry Additions 67
1.7.1 Sinopec Boosts Refining Capacity To 232 Mln Tons 68
1.8 Oil Refineries 69
1.8.1 Economic Environment Of Constrained Refinery Capex 69
1.9 Diesel 70
1.9.1 Maximizing Diesel Production Through Integrated Hydroprocessing 70
1.10 Hydrotreating 72
1.10.1 Hydrotreating Process Description 74
1.10.2 Typical Causes Of Deactivation Of Hydroprocessing Catalysts 74
1.10.3 Typical Methods Of Performance Recovery and Regeneration Of Hydroprocessing Catalysts 75
1.10.4 Hydrotreating Catalysts 76
1.10.5 Hydrocracking 77
1.11 Fluid Catalytic Cracking (FCC) 78
1.12 Reforming 79
1.13 Refinery Costs and Supply 80
1.14 Fuel Consumption In Transportation 81
1.14.1 Changing Trends 82
1.14.2 Rising Consumption Of Petroleum Based Derivatives 83
1.14.3 Demand For Maintaining High Octane Number 83
1.14.4 Catalytic Hydrotreating 86
1.15 Natural Gas Energy Market Growth 89
2. Refinery Catalysts Market Shares And Forecasts 91
2.1 Refinery Catalysts Market Driving Forces 91
2.1.1 Change Is the Only Constant 93
2.1.2 Shift In Refiners' Raw Material Consumption Toward Heavier Feedstocks 95
2.1.3 Lower Sulfur Specifications Worldwide 96
2.2 Refinery Catalysts Market Shares 96
2.2.1 Shell CRI-Criterion Hydrocracking Catalysts 100
2.2.2 Grace 100
2.2.3 Chevron and Grace Formed Advanced Refining Technologies (ART), 101
2.2.4 Albemarle Addresses Demand For Refinery Catalysts 102
2.2.5 Catalysts and Licensing LLC, ExxonMobil 102
2.2.6 Criterion 103
2.2.7 Criterion NAPHTHA 104
2.2.8 ExxonMobil Corporation 105
2.2.9 BASF 105
2.2.10 BASF FCC Refining Catalysts 105
2.2.11 Haldor Topsoe 106
2.2.12 Johnson Matthey 106
2.2.13 SINOPEC Catalyst Company 106
2.2.14 UNICAT Catalyst Technologies, Inc. 107
2.3 Refinery Catalysts Market Forecast 2016 107
2.3.1 Albemarle REACT™ has been successfully used to reactivate 115
2.4 Refinery Catalyst Molybdenum and Momentum 115
2.5 Hydroprocessing Refinery Catalysts 126
2.5.1 Hydrocracking Catalysts 128
2.5.2 Hydrodesulphurization Catalyst 129
2.5.3 Production of Ultra-Low-Sulfur Diesel ULSD to Meet Global Diesel Needs 129
2.5.4 Hydrocracking Integration 131
2.5.5 Hydrocracking Meeting Refining Challenges 131
2.5.6 Hydrotreating 131
2.6 Hydroprocessing Refinery Catalyst Market Shares 132
2.6.1 Albemarle Hydroprocessing Catalyst Area 135
2.6.2 Albemarle Addressing Is The Need For More Hydroprocessing Capacity 135
2.6.3 Haldor Topsoe 136
2.6.4 Topsoe Reforming 137
2.6.5 Shell / Criterion 137
2.6.6 Shell CRI Catalyst Company Part of CRI/Criterion Inc., Ethylene Oxide 139
2.6.7 Shell Group Criterion Catalysts & Technologies (Houston) 139
2.6.8 ART 140
2.6.9 Chevron/Grace Venture, ART 142
2.6.10 Axens’ Hydrocracking Technologies 142
2.6.11 Axens Diesel Hydrotreating 142
2.6.12 Honeywell UOP 143
2.6.13 Zeolyst 144
2.6.14 Clariant / Süd-Chemie 144
2.6.15 UOP the CANMET 145

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