Download - 02 JM Intro & Syngas Heritage
Johnson Matthey introduction and heritage
in syngas
Matthew Humphrys
25 Mar 2015
Westin Hotel Gurgaon, India
Johnson Matthey
• World class technology in catalysts, fine chemicals and
precious metals
• 11,300 employees in 30+ countries
• £11b turnover
• £3b sales (excl pgm)
• £427m pre tax profit
• Strategy for growth
Emission Control
Technologies
Process
Technologies
Precious Metal
Products
Fine
Chemicals
New
Businesses
Chemicals
• Syngas
• Johnson Matthey
Davy Technologies
• Chemical Catalysts
(including Formox)
Oil and Gas
• Refineries
• Purification
• Tracerco
Services
• Platinum Marketing
and Distribution
• Refining
Manufacturing
• Noble Metals
• Colour Technologies
• Chemical Products
• Active Pharmaceutical
Ingredient (API)
Manufacturing
• Catalysis and Chiral
Technologies
• Research Chemicals
• New Business
Development
• Water
• Battery Technologies
• Fuel Cells
• Light Duty Catalysts
• Heavy Duty Catalysts
• Stationary Emissions
Control
Divisional structure
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History of process technologies
JM pgm
catalysts
Process
Technology
Division
Davy Process
Technology Process technologies,
process
engineering and licensing
2006
Formox Formaldehyde
catalysts,
licences and
technologies
2013
Intercat Additives for
FCC applications
2010
ICI Synetix Base metal
catalysts
2002
Ammonia
• KATALCOJM catalysts
• KATALCOJM PERFORMANCE
• JM technology
• SINOx SCR systems
• Tracerco
• JM-TKIS partnership
Urea & CO2
• PURAVOC H2 removal
• Standard VOC & CONCATTM for
methanol abatement
• Formaldehyde/UFC-85 plants
• Formaldehyde catalyst
• PURASPEC CO2 purification
Methanol – catalysts & technology
• KATALCOJM catalyst #1 choice
• Recent product launches
• KATALCOJM 33-1
• KATALCOJM 89-6
• KATALCOJM APICO 51-100
• JM technology is the market
leader
• KATALCOJM and JM Davy drive
development
• Significant new capacity, coal
feedstock, new downstream
uses
Substitute natural gas (SNG)
• Long history supplying CRG
catalyst & technology
• JM Davy/British Gas
• Strong demand for new
plants where:
• High gas prices
• Coal, petcoke, coke-oven gas
available
• CRG methanation
technology licensed for new
projects in China & India
• Reliance refinery
JM in the UK
Billingham
Clitheroe
JM & ICI central to development of the Ammonia industry
through technology, catalysts and production
JM in India
“Make in India: Zero defect and Zero effect”
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Billingham Concept - 1920
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1940’s ICI Reforming technology development
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Early 1960s reforming flowsheet
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Steam Reforming process licencing
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Mid -1960s ICI-patented LTS
1960’s Technology development continues
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• 3 of world’s 1st 1,000 stpd Kellogg
plants, establishing the modern
flowsheet
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1970s ICI HAZOP process
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1980s – Process Developments
LCA small scale process
AMV low energy process
1990’s – Specialisation
• The two industry founders chose their futures
• BASF focuses on speciality chemicals and its
integrated chemicals manufacturing sites
• Sells it’s catalyst business to JM (then ICI) in 1997
• Johnson Matthey specialises in catalysts and
associated technology
• Acquires ICI Syngas catalyst business in 2002
• Acquires Davy Process technology in 2006
• Acquires Formox formaldehyde in 2012
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Heritage Plants Operated by ICI
Plant Country Design Capacity, Te/day
Start-up
Severnside 1 UK ICI 300 1962
Severnside 1A UK Bechtel 570 1965
Billingham 1 UK Kellogg 900 1966
Billingham 2 UK Kellogg 900 1966
Billingham 3 UK Kellogg 900 1967
Courtright 1 Canada Kellogg 900 1967
Immingham UK Kellogg 570 1967
Kanpur 1 India India 415 1969
Kanpur 2 India India 415 1969
Gibson Island Australia Pritchard 540 1969
Newcastle Australia Kellogg 540 1969
Billingham 4 UK Jacobs 1100 1977
Modderfontein S Africa Kellogg 1100 1978
Cork Eire Kellogg 1350 1979
Kanpur 3 India India 415 1981
Courtright 2 Canada ICI 1100 1985
Severnside LCA 1 UK ICI 450 1988
Severnside LCA 2 UK UK 450 1988
Technology Alliances
• TKIS (Uhde) – World’s leading Ammonia contractor
• Catalyst & technology agreement since 1998
• Joint technology development, including TKIS’s Dual
Pressure Process for 3,300TPD plants
• Stronger technical support to Uhde & Uhde customer
• Revamp capabilities, catalyst and engineering
• Davy – World’s leading Methanol process contractor
• Own roots in the syngas industry (Davy Powergas)
• Technology / Supply agreements since 1960’s
• Now owned by JM since 2006
Uhde Ammonia Plants with JM Alliance
Plant Country Capacity, Te/day Start-up
ABF Malaysia 1000 1985
Puyang China 1000 1990
BASF Belgium 1800 1991
EFC 1 Egypt 1200 1998
Abu Qir 3 Egypt 1200 1998
QAFCO 4 Qatar 2000 2004
Tecen Turkmenistan 600 2004
SAFCO 4 Saudi Arabia 3300 2006
EFC 2 Egypt 1200 2006
Alexfert Egypt 1200 2006
Helwan Egypt 1200 2007
MOPCO Egypt 1200 2008
Ma’aden Saudi Arabia 3300 2011
SORFERT 1 Algeria 2200 2012
SORFERT 1 Algeria 2200 2013
Fertil UAE 2200 2013
MOPCO 2, 3 Egypt 2x1200 2013+
JM Catalyst Manufacture in the UK
Catalyst manufacture in UK
1940s, 50s
Catalyst manufacturing started.
First methanol syn catalyst.
Focus on own (ICI) plants.
1960’s - 2002
Upgraded for commercial catalysts.
Expansion of range to cover all syngas and others.
Steady growth in capacity, new products
2002 – 2008
Accelerated investment under JM.
Investment in reforming, GTL, shift.
2008 - 2015
Significant investment & expansion.
Methanol syn, reforming, Substitute Natural Gas,
purification
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JM Catalyst Manufacture in India
Catalyst manufacture in India
1984
Catalyst manufacturing started.
Integrated with fertilizer plant.
1994 – 2002
Separated from fertilizer plant.
Own Infrastructure.
Independent operations.
2002 – 2009
Investment under JM.
Purification expansion.
Plant automation & uprating.
2009-2015
Significant investment & expansion.
Reforming, pre-reforming, purification
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“Make in India: Zero defect & Zero effect”
• Commitment to the
country with investment
and employment
• International standards of
quality, safety,
environment, sustainability
• Successful exporter
• Responsiveness to local
catalyst demand, without
import taxes
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JM heritage core to the ammonia industry
Johnson Matthey – our future
• In 2017 JM enters its 3rd Century
• Our strategy that will take us into our 3rd Century of value-
adding sustainable technologies is summarized by:
• The 3C’s: