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Table of Contents
1. Introduction..................................................................... 4
2. Overview.......................................................................... 6
a. History of Catalysis..................................................... 8
b. Catalyst Attributes..................................................... 12
d. Sustainability............................................................. 17
3. Biorenewables............................................................... 18
4. Environmental Catalysts................................................ 20
5. Fine Chemical Catalysts................................................ 22
6. Catalysts for Fuel Cells.................................................. 25
7. Oleochemical Catalysts................................................ 27
8. Oxidation & Dehydrogenation Catalysts....................... 31
9. Petrochemical Catalysts............................................... 35
10. Polyolefin Catalysts....................................................... 38
11. Purification Adsorbents................................................. 40
12. Refining Catalysts.......................................................... 44
13. Syngas Process Catalysts............................................ 48
14. Custom Catalysts.......................................................... 50
15. Technical Service & Support......................................... 52
16. Precious Metals Services.............................................. 55
17. Contact Us.................................................................... 57
Introduction
4
Technical Service
In the selection and optimization of process catalysts
and adsorbents, companies turn to BASF. Customer
collaborations are essential in establishing and maintaining
successful relationships. Constant contact allows for
immediate responses to challenges. With onsite
customer visits, we perform thorough production
analyses, and suggest improvements for:
Increasing yield
Improving selectivity
n Enhancing throughput
n Reducing waste
n Minimizing costs
n
n
Worldwide Resources
As part of BASF The Chemical Company, the Catalysts
division offers global assets for the entire value chain. Our
Overview of
Catalysis
6
Biocatalysis
Comprises the smallest portion (~2%) of todays overall
world catalyst market; uses enzymes or bio-organisms in
fermentative processes.
Homogeneous catalysis
Represents less than 10% of the catalyst market and often
faces process operation and catalyst handling issues that
limit its use; the catalyst must be dissolved in the reaction
medium.
Heterogeneous catalysis
Accounts for about 80% of all catalytic processes
and offers distinct improvements over homogeneous
catalytic processes.
Advantages include:
High stability and regenerability
Easy removal from the reaction medium
8% Other
2% Biocatalysis
10% Homogeneous catalysis
History of Catalysis
When was the concept of catalysis established? This is a
difficult question to answer quantitatively. Does it start with
the ancient belief in the ability of the philosophers stone
to convert ordinary metals into precious gold? Or, does its
origin lie in the Egyptians use of yeast to convert sugar
in fruit juice into alcohol? Regardless of its beginnings,
the science of catalysis has revolutionized chemical
applications.
Milestones in Ind
10
1835
1888
1894
1906
First definition of
catalysis by Jns
Jakob Berzelius
Wilhelm Ostwald
(Nobel Prize 1909)
defines catalysis as
the acceleration of a
chemical process
proceeding slowly
through the presence
of an extraneous
substance
Oxidation of ammonia
to produce nitric acid
by Wilhelm Ostwald
1974
1972
1968
1953
he three-way
T
catalytic converter
for removing
pollutants from
gasoline engine
exhaust is
commercialized
by BASF
Christian Anfinsen,
Stanfort Moore,
and William H.
Stein receive the
Nobel Prize for
their work on the
catalytic activity of
the enzyme
ribonuclease
Origins of
asymmetric
catalysis (synthesis
of L-dopa) in the
form of studies by
William S. Knowles
Low-pressure
polymerization of
alkenes to polymers
by Karl Ziegler and
Giulio Natta (joint
winners of Nobel
Prize 1963)
1991
1997
2001
2001
he first commercial
T
use of metallocene
catalysts leads to
novel polymer
structures
aul D. Boyer,
P
John E. Walker,
and J.C. Skou
receive the Nobel
Prize for studies
on enzymes in ATP
synthesis
illiam S. Knowles,
W
R. Noyori, and K.
Barry Sharpless
receive the Nobel
Prize for catalysis
with asymmetric
molecules
Controlled
optimization of
biocatalysts by
methods of genetic
engineering
194
Vladimir Ipa
and Herma
Pines succ
catalyticall
alkylating
hydrocarbo
produce pe
with a high
number
200
Yves Chau
Robert S. G
and Richar
Schrock re
the Nobel P
studies of c
in metathes
reactions
dustrial Catalysis
1908
1910
1913
1920
40
atieff
an
ceed in
ly
1936
Eugene Houdry
develops fluid
catalytic cracking
(FCC)
ons to
etroleum
h octane
05
uvin,
Grubbs,
rd R.
eceive
Prize for
catalysis
sis
1931
arl Bosch and
C
Friedrich Bergius
receive the
Nobel Prize for
the development
of catalytic
high-pressure
reactions
1929
1922
Irving Langmuir
(Nobel Prize 1932)
studies the
oxidation of
carbon monoxide
2007
2007
2009
2010
atalytic
C
denitrification of
diesel engine
exhaust gases
11
Catalyst Attributes
In addition to high activity and good selectivity, a quality
catalyst possesses long-term chemical and mechanical
stability, and suitable shape. Although selectivitys ability
for making a small change into a noteworthy gain is
considered as one of the most important attributes, all
catalytic properties supply great economic significance.
Catalysts are either:
n
Tablet
Ring
Grain
Extrudate
Cylinder
Sphere
Monolith
12
Raw materials
Great care must be taken in the selection of the initial materials used in the catalyst production. For example,
catalyst poisons are detrimental to any improvements generated by the catalyst. Therefore, they must not be introduced
via feedstocks.
Pore structure of the catalyst
Starting materials initially pass through the pores to the active catalyst surface and end products later follow via the
same route. Lack of consistency in the pore structure can slow down the reaction and/or modify the catalytic action.
Chemical composition of the solid, comprising the catalytically active elements
Todays high-performance catalysts are typically multi-component systems composed of several active phases
which are additionally doped with numerous promoters. This introduces new factors that must be dealt with in
catalyst production.
Defined chemical composition of the active surface (both outer and inner pores)
This is very important for the functioning of the active sites, since the correct composition of the solid alone is
insufficient for high activity and selectivity.
Stability of the active phase
The morphological stability of the active catalyst phase is a prerequisite for producing a satisfactory lifetime.
Mass and heat transfer in the reactor and over the catalyst
A detailed procedure should be followed for the optimization of a catalyst system. This can be done by either creating
the most favorable operating conditions or by adapting the catalyst to perform better in the existing conditions.
Mass and
Heat
Transfer
Stability of
the Active
Phase
Pore Structure
of the Solid
Solid
Catalyst
Raw Materials
Surface
Composition
Figure 3:
Factors that influence a
catalysts performance
Chemical and
Mechanical
Stability
Chemical
Composition
13
Fundamentals of
Heterogeneous Catalysis
In simplest terms, a catalyst is a substance that, without
itself being consumed, accelerates the reaction rate
by interacting with reactants. The catalyst does this by
providing a chemical with a new path that allows the
starting materials to be more easily converted to the
end product.
In Dbereiners lighter, a route is found by the contact of
hydrogen and oxygen with the platinum catalyst. Without
catalysts, the two gases do not react (or more accurately,
react infinitely slowly) to give water.
The three main types of catalytic processes are:
n
14
diffusion
diffusion
reaction
2 CO2
2 CO + O2
adsorption
desorption
catalyst surface
energy
without catalyst
with catalyst
EA
energy
barrier
EA, Cat
heat of
reaction
X
Y
A: Starting material
B: Product
X: Chemical interaction between A and catalyst
Y: Chemical interaction between B and catalyst
reaction path
15
Starting
Materials:
CO+H2
Catalysts
End Products
Nickel
CH4 (Methane)
Cu/ZnO/Al2O3
CH3OH (Methanol)
Iron or Cobalt
CnH2n+2 (Fuel)
16
Sustainability
At BASF, sustainability is an interweaving of strategic goals for economic success, environmental protection, and social
responsibility. For a process to be sustainable, it must efficiently use resources, while leaving sufficient materials for
future generations. Catalysis is the key element to make this happen. BASFs Catalysts division meets the challenge
by offering technologies that protect the air we breathe, and ensure efficient production of a wide variety of chemicals,
plastics, and other products.
In the industrial chemical market, catalysts are leading the way to sustainability by:
n
Unsustainable Situation:
Sustainable Result:
Sustainable Result:
17
Biorenewables
18
Biofeedstocks
Biofeedstocks include triglycerides (oils and fats), sugar,
and cellulosic materials. In addition to our hydrogenation
catalysts (Figure 7) and purification adsorbents, BASF
offers a comprehensive line of catalysts for sugarbased
chemical value chains, including the conversion of sugars
to sorbitol.
Biofuels
BASF offers catalytic solutions for the processing of
different types of biofuels. One such example is the
heterogeneous catalyst that catalytically transesterifies
triglycerides with methanol for Fatty Acid Methyl Ester
(FAME) production (Figure 8).
Catalytic
Transesterification Process
H2C
OOCR
HC
OOCR
H2C
OOCR
Triglyceride
BASF
Heterogenous
Catalyst
Methanol
Glycerol
3 H3C
OOCR
FAME
Biodiesel
Figure 7: Example of a hydrogenation
catalyst for biofeedstock conversions
19
Environmental
Catalysts
20
Calcination plants
Caprolactam plants
Cement plants
Gas turbines
Glass trough
Railroad engines
Ship diesel
Steam crackers
Steel mills
Gas turbines
Power plants
Process industries
21
Fine Chemical
Catalysts
22
Research Quantities:
Commercial Quantities:
ontact one of the
C
following regional offices
n
Asia: +912226164159
EMEA: +390641992605
USA: +18003368559
Proven effectiveness in a broader range of solvents (high activity and process productivity preserved) Figure 11
100
BGR
catalyst
80
Classical
catalyst
60
40
160
Methanol
MeOH
140
120
Ethyl acetate
100
N-Methyl-2Pyrrolidone
(NMP)
80
60
40
20
20
5%Pd/CP BGR
23
Maintenance of high uptake capacity in either aqueous (Figure 12) or organic (Figure 13) solution
300
300
Resin
MSA FC Si-1
200
150
150
100
500
500
10
15
20
Time (min)
MSA FC Si-1
200
100
Resin
250
Pd (ppm)
Pd (ppm)
250
10
15
20
Time (min)
24
Catalysts for
Fuel Cells
25
CO Removal
CO-selective methanation
CO-selective oxidation
Reforming
BASF R Series catalysts, both base and precious metal
materials, offer outstanding results in the production of
hydrogen from hydrocarbon feedstocks, such as natural
gas, liquefied petroleum gas (LPG), gasoline, diesel and
alcohols. The benefits of R Series products:
n
CO-Shift Reactions
BASF S Series catalysts, both base and precious metal
materials, provide improved solutions for both low and high
temperature CO-shift reactions. The benefits of S Series
products:
n
26
Robust material
Long lifetime
Outstanding performance
Tailored solutions
Electrocatalysts
BASF also offers a wide range of highly active cathode
and anode electrocatalysts on corrosion resistant support
materials.
Oleochemical
Catalysts
27
High activity
Our formed catalysts (copper chromite and copper on silica and alumina
supports) for fixed beds offer:
n
Nickel Catalysts
Our nickel-based catalysts are characteristically used as a final purification step
in fixed bed hydrogenation of low levels of carbonyl compounds in fatty alcohols.
They are typically pre-activated to increase activity levels.
Zinc Catalysts
Our zinc-based catalysts are essential to ester hydrogenation that requires
carbon-carbon unsaturation retention.
28
Carbohydrate hydrogenation
29
Application
Activity
Selectivity
Standard
High
High
Selective
Partial hydrogenation, e. g. to
minimize saturates
Good
Very high
High-Durability
Good
High
Low Nickel
Very high
High
(based on
Ni content)
Good
High
Application
Activity
Standard
High
Impurity Resistance
Good
Low Nickel
30
Oxidation &
Dehydrogenation
Catalysts
31
heat exchanger 1
heat exchanger 4
heat exchanger 2
blower
SO2
converter
heat exchanger 3
final
absorption
tower
32
intermediate
absorption
tower
Startup assistance
Technical support
aleic Anhydride
M
Uses: Unsaturated Polyester Resins (UPR) for the
electronics and construction industries
utanediole (BDO)
B
Uses: Polyurethanes production
etrahydrofuran (THF)
T
Uses: Spandex fibers to produce products, such as elastic
sportswear
umaric Acid
F
Uses: Paper resins and food acid
thers: MANbased copolymers, succinic anhydride,
O
and other chemical intermediates
Oxychlorination Catalysts
BASF offers a full range of OxiStar oxychlorination
catalysts and diluents for the production of ethylene
dichloride (EDC) using fixed bed technology. As the
leading performer in fixed bed processes, we provide:
n
33
34
Petrochemical
Catalysts
Hydrogenation
Dehydrogenation
Amination
Oxidation
n
n
n
Halogenation
Dehydration
Hydration
35
Hydrocarbon
Hydrogenation
n
Resin hydrogenation
Dehydrogenation,
Dehydration, Oxidation
n
Alcohols
ASF-Linde Propane
B
Dehydrogenation Process
NAP catalyst for butane and
S
propane dehydrogenation
Ethanol-to-ethylene
Inorganics
Oxo alcohols
MPO (Acetophenone to
S
phenylethanol to styrene)
Silicones
Brine polishing
Amines
Aliphatic amines
romatic amines (e.g. Aniline,
A
TDA)
lternate chlorofluorocarbons
A
(CFCs)
H2O2
hlorinated organics
C
(e.g. chloroacetic acid)
Others
Polishing
Acrylamide
Others
Others
Crudes
Primary BB
Gas
Syngas
Secondary BB
Products
Acetylene
Butanediol
Hydrogen
H2O2
Ammonia
Methanol
Oxo alcohols
Oil
Naphtha
Coal
Alternate CFCs
Cyclohexane
Fuels
Benzene
Aromatics
Coal tar
36
Vinyl acetate
Alkyl amines
Olefins
Lubricants
Methyl amines
Cumene, Styrene
Aniline
Toluene
TDI
Xylene
PTA, PA
Application
Ni 32XX/Ni 52XX
Dearomatization
H0-XX/E Series
Al 39XX
Alcohol Dehydration
Pd 09XX
Cu/CuCr Series
Oxo Alcohols
Cu 08XX
Aromatic Amines
Pd/Zeolite
H 2O 2
CBA 300/400
37
Polyolefin
Catalysts
38
Low or no fines
Lynx 1030
4
Xylene Soluble
Lynx 1020
Film
BOPP
Lynx 1010
IM
Fiber
Lynx 1000
Impact Copolymer*
HC
10
* Homopolymer MF
20
30
Melt Flow
40
50
39
Purification
Adsorbents
40
Long-life
41
Mercaptans
Sulfides, Disulfides
Thiophenes
Oxygenates (Alcohols,
Aldehydes, Ketones, etc.)
Organosilicates
Arsine
Oxygen
Hydrogen
Phosphine
42
Application
Products
Dehydration
Hydrocarbon Recovery
H 2O 2
Selexsorb
COS, D-1275/D-1280, Prosorb, R3-12, R3-16,
Selexsorb AS, Selexcat, E-315/R9-12
CO, CO2
Chloride
HF
HF-200, HF-200XP
Fluoride
CPN, DD-6
Arsine, Phosphine
O 2, H 2
Oxygenates
Nitriles, Ammonia
Organosilicates
Selexsorb Si
TBC (Styrene)
Selexsorb ST
Oleflex
DD-710
Aromatics Purification,
BTX, Xylenes, Cumene
Claus Catalysts
S-100,
S-100SR, S-400, DD-431,
DD-831, DD-931, SRC-99ti, Ti-1100e
Catalyst Substrates
Catalyst Precursors
Bed Supports
T-162, ABS
Chromatographic
CG-20
Refinery Off-Gas
R3-81, R8-21
Acetylene Off-Gas
R0-20, R3-15
Air Separation
13X
43
Refining
Catalysts
44
FCC Catalysts
Additives
n
n
FCC Catalysts
Propylene maximization
aximum gasoline production with maximum
M
sulfur reduction
ow microfines generation for improved high
L
stack opacity
Technical Services
Additives
BASF offers a complete range of FCC additives to meet
refiners environmental and performance requirements
addressing:
n
Improved fluidization
Sulfur reduction
Outstanding CO promoters
n
n
45
Gas Oil
DMS
FCC CATALYSTS
BASF is a global industry
leader in FCC catalysts
with unparalleled
commitment to delivery of
cutting edge technology
and service to the refining
industry
Resid
PROXSMZ
NaphthaMax
NaphthaMax III
HDXtra
PetroMax
Flex-Tec
Defender
Endurance
Stamina
Aegis
Fortress
BituPro
FCC CO-CATALYSTS
Co-Catalysts have
similarities with both
Additives & Catalysts but
stand alone as a category
of products
Converter
HDUltra
HDUltra-R
FCC SOLUTIONS
FCC Solutions are
customized solutions
built on unique synergies
of BASF Technology
platforms offering optimal
performance
ADDITIVES
Complete range of FCC
additives to meet refiners
environmental and
performance requirements
LMF
NaphthaClean
MPS
EZ Flow
LSA
USP
MOA
CLEANOx
LNP
SOXCATExtra
46
OTHER
DMS
PROXSMZ
DMS +
PROX-SMZ
Canadian
Oil Sands
MSRC
DMS +
PROX-SMZ
Gasoline
DMS
Distillate
PROXSMZ
Low
Micro
Fines
OTHER
Gasoline
Sulfur
Reduction
DMS
Propylene
Maximization
Performance
Enhancing
Environmental
Compliance
DMS
47
Syngas
Process
Catalysts
48
Natural Gas
BASF provides catalytic advancements for syngas, a key
intermediate in emerging natural gas technologies, such as:
n
GasToLiquids (GTL)
Methanoltoolefins
Coaltoliquids
Fuel cells
Pre-Reforming
Syngas plants utilize BASFs prereforming catalysts in the
production of:
n
Methanol
Ammonia
Hydrogen
Other chemicals
Biomass gasification
Coal gasification
49
Custom
Catalysts
50
51
Technical Service
& Support
52
Manufacturing
R&D Sites
UK
US
Europe
Spain
Netherlands
Germany
Italy
Korea
China
Japan
India
North
America
South
America
Thailand
Asia
Pacific*
Brazil
Africa
South
Africa
*Includes joint ventures
53
Inventory management
Quality Assurance
BASF is recognized worldwide for its quality that is
backed by:
54
ISO certification
Operator training
Precious
Metals
Services
55
Cinderford (UK)
Rome (Italy)
Shanghai (China)
56
Contact Us
Process Catalysts
Americas
Sales & Marketing
BASF Corporation
25 Middlesex/Essex Turnpike
P.O. Box 770
Iselin, NJ 088300770
Tel: +17322055000
Fax: +17322055687
Email: catalystsamericas@basf.com
Customer Service
BASF Corporation
100 Campus Drive
Florham Park, NJ 07932
Tel: +18008899845/+19732457445
Fax: +18643325087
Asia Pacific
Sales & Marketing
BASF East Asia Regional Headquarters Ltd.
45th Floor, Jardine House
No. 1 Connaught Place
Central, Hong Kong
Tel: +85227310191
Fax: +85227315634
Email: catalystsasia@basf.com
Customer Service
BASF East Asia Regional Headquarters Ltd.
45th Floor, Jardine House
No. 1 Connaught Place
Central, Hong Kong
Tel: +85227311561
Fax: +85227319634
Trading Offices
BASF Corporation
25 Middlesex/Essex Turnpike
Iselin, NJ 08830-0770
Tel: +1-732-205-5000
Engelhard Metals Limited
63 St. Mary Axe
London EC3A 8NH
England
Tel: +44-207-456-7300
BASF Metals Japan Limited
24th Floor, World Trade Center Building
2-4-1 Hamamatsu-cho, Minato-ku
Tokyo 105-6124, Japan
Tel: +81-3-3578-6661
BASF Metals (Shanghai) Limited
239 Luqiao Road
Jinqiao Export Processing Zone
Shanghai 201206
P.R. China
Tel: +86-21-6109-1885
BASF Metals GmbH
Grafenauweg 6
6300 Zug
Switzerland
Tel: +41-41-710-82-77
BASF Industrial Metals OOO
Kadashevskaya nab. 14/3
Moscow 119017
Russia
Tel: +7-495-2256490
57
About Us
BASFs Catalysts division is the worlds
leading supplier of environmental
and process catalysts. The group
offers exceptional expertise in the
development of technologies that
protect the air we breathe, produce the
fuels that power our world, and ensure
efficient production of a wide variety
of chemicals, plastics, and other
products. By leveraging our industryleading R&D platforms, passion for
innovation, and deep knowledge of
precious and base metals, BASFs
Catalysts division develops unique,
proprietary catalyst and adsorbent
solutions that drive customer success.
BASF - The Chemical Company
58
Americas
BASF Corporation
25 Middlesex/Essex Turnpike
Iselin, New Jersey 08830, USA
Tel: +1-732-205-5000
Fax: +1-732-205-7725
Email: catalysts-americas@basf.com
Asia Pacific
BASF East Asia Regional HQ Ltd.
45th Floor, Jardine House
No. 1 Connaught Place
Central, Hong Kong
Email: catalysts-asia@basf.com
Tel: +852-2731-0191
Europe, Middle East, Africa
BASF SE
67056 Ludwigshafen, Germany
Email: catalysts-europe@basf.com
Tel: +49-621-60-21153
www.catalysts.basf.com/process