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ReportsnReports - Global Market for Catalyst Regeneration

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					Global Market for Catalyst Regeneration

This BCC Research study focuses on the catalyst regeneration business. Global value
demand for catalysts (both fresh and regenerated) will grow 7.9% yearly from the current
value of $11.5 billion to $16.9 billion through 2010. This is based on increased production of
end-use products and a shift toward higher-value catalyst materials. Polymerization
catalysts will grow the fastest while chemical synthesis catalysts will surpass petroleum
refining types as the largest segment.

This report study analyzes the world regenerated catalyst business. It presents historical
demand data for 2002, 2003, 2004 and 2005, and forecasts to 2010 according to catalyst
management service, product and application (e.g., fluid cracking, hydroprocessing,
alkylation, reforming and organic synthesis, oxidation, synthesis gas, hydrogenation,
automotive exhaust and flue/waste treatment); also by market sector, material, site,
technology and by world region, respectively. The study also quantifies the various options
for managing spent catalysts.

The study examines the market environment, details industry structure and market share,
and profiles leading industry competitors including Eurecat, Tricat, SCR-Tech, CRI, W.R.
Grace, Akzo Nobel, Johnson Matthey, Engelhard, Royal Dutch/Shell, BP, ChevronTexaco,
Degussa, Dow Chemical, DuPont, Sasol, Eni Technologies and Haldor Topsoe. It assesses
the role of catalyst regeneration as a key input for the production of high-quality, clean
transportation fuels and environmental clean-up of dangerous pollutants.

SCOPE OF STUDY
This report covers:
 Regenerated catalyst use in processing of crude oil (including non-conventional sources
   such as tar sands and heavy oil reservoirs), chemical/petrochemical synthesis,
   automotive exhaust gas treatment, and flue gas/waste treatment,
 An extensive overview of the U.S. and global catalyst regeneration markets,
 The global market for catalyst regeneration, with data forecasted through 2010,
 The top companies in the catalyst regeneration business,
 A detailed patent analysis.

METHODOLOGY INFORMATION SOURCES
The findings and conclusions of this report are based on information gathered from a cross-
section of catalyst developers, manufacturers, distributors, end users and other informed
sources. Interview data were combined with information gathered through an extensive
review of secondary sources such as trade publications, trade associations, company
literature and on-line databases to produce the baseline market estimates contained in this
report.
With 2005 as a baseline, projections for each market segment were developed for 2005
through 2010. They are based on a combination of a consensus among the primary
contacts, combined with BCC Research’s understanding of the key market drivers and their
impact from a historical and analytical perspective. The analytical methodologies used to
generate market estimates are based on a detailed projection of world economy and trade.
All dollar projections presented in this report are in 2004 constant dollars.
ANALYST CREDENTIALS
Edward Gobina is a full U.K. Professor of Chemical and Process Engineering and has more
than 20 years’ research and teaching experience in environmental engineering,
petrochemical reaction engineering and catalytic membrane technology.
He has been published extensively, with more than 100 relevant publications in
international scientific journals. Gobina is the author of four major patents on membrane-
related technologies and 16 previous BCC Research reports covering the entire chemical
energy infrastructure chain from gas sensors and monitoring instruments to advanced
exploration and downhole technology and hydrogen infrastructure.
Professor Gobina is a member of the European Membrane Society (EMS), the North
American Membrane Society (NAMS) and the New York Academy of Sciences (NYAS). He is
the current director of the Centre for Process Integration and Membrane Technology
(CPIMT) in the School of Engineering and the Built Environment at Robert Gordon University
(Aberdeen, Scotland).

Table Of Contents
Chapter- 1: INTRODUCTION – Complimentary
STUDY GOALS AND OBJECTIVES
REPORT HIGHLIGHTS
REASONS FOR DOING THE STUDY
CONTRIBUTION OF THE STUDY AND FOR WHOM
SCOPE AND FORMAT
METHODOLOGY AND INFORMATION SOURCES
ANALYST’S CREDENTIALS
RELATED BCC RESEARCH EFFORTS
BCC ONLINE SERVICES
DISCLAIMER

Chapter- 2: SUMMARY
Table 0 : GLOBAL MARKET FORECAST FOR CATALYST REGENERATION BY SITE
TECHNOLOGY, THROUGH 2010
Figure 0 : GLOBAL MARKET FORECAST FOR CATALYST REGENERATION BY SITE
TECHNOLOGY, 2002-2010

Chapter- 3: OVERVIEW
INTRODUCTION
OVERVIEW OF REGENERATED CATALYST USE
OVERVIEW OF FRESH AND REGENERATED CATALYSTS COSTS
OVERVIEW OF SPENT CATALYST USE OPTION
IMPORTANCE OF SPENT CATALYST REGENERATION AND MANAGEMENT SERVICES
OVERVIEW OF THE REGENERATED CATALYST CHARATERISTICS AND PROPERTIES
OVERVIEW OF COMMERCIAL REGENERATION TECHNOLOGIES
OVERVIEW OF SPENT CATALYST EVALUATION
IMPORTANT ECONOMIC INDICATIONS FOR WORLD TRADE
OVERVIEW OF INTERNATIONAL CURRENCY EXCHANGE RATES
OVERVIEW OF THE METAL MARKET
PLATINUM GROUP METALS
OVERVIEW OF INORGANIC CHEMICAL COSTS
RARE EARTHS AND MAGNESIUM COMPOUNDS AND CHEMICALS
OVERVIEW OF SPENT CATALYST COMPOSITIONS
OVERVIEW OF CATALYST ACTIVITY DETERIORATION AND REGENERABILITY
OVERVIEW OF THE SIGNIFICANCE OF CATALYST PHYSICAL PROPERTIES
OVERVIEW OF THE CAUSE AND EFFECT OF CATALYST ACTIVITY DETERIORATION
CATALYST REGENERATION: ADVANTAGES AND DISADVANTAGES
OVERVIEW OF FUEL SULFUR LIMITS IN SELECTED COUNTRIES
OVERVIEW OF REGENERATED CATALYST DEMAND BY MARKET SEGMENT
OVERVIEW OF REGENERATED CATALYST USE PRODUCT MATRIX
HISTORY OF THE CATALYST REGENERATION BUSINESS
SOME IMPORTANT DEVELOPMENTS FOR THE CATALYST REGENERATION BUSINESS
THE FUTURE
Table 27 : OVERVIEW OF GLOBAL DEMAND FOR CATALYST REGENERATION BY
REGION, THROUGH 2005

Chapter- 4: REGULATORY ISSUES
INTRODUCTION
CLEAN AIR INTERSTATE RULE (CAIR)
CLEAN AIR AMENDMENTS ACT OF 1990
OXYGENATED GASOLINE PROGRAM/REFORMULATED GASOLINE PROGRAM
DIESEL FUEL REGULATIONS
RESOURCE CONSERVATION AND RECOVERY ACT (CERCLA: 42 U.S.C. S/S 6901 ET SEQ. –
1976)
CATALYST RECLAMATION AND DISPOSAL
THE JEFFORDS AMENDMENT
CLEAN NONROAD DIESEL RULE
CLEAR SKIES ACT OF 2003
CLEAN WATER ACT
EUROPEAN LEGISLATION COVERING SPENT CATALYSTS
EPA REVISES LIST OF MAJOR SOURCE CATEGORIES
THE ENERGY POLICY ACT OF 2005

Chapter- 5: INDUSTRY STRUCTURE AND COMPETITIVE RATES
INTRODUCTION
LABORATORY SPENT CATALYST REGENERATION
PHYSICAL AND CHEMICAL CHARACTERISTICS OF REGENERATED CATALYSTS
CONTRIBUTORY FACTORS IN ACTIVITY REGAIN AFTER REGENERATION
CHEMICAL COMPOSITION OF SPENT CATALYSTS IN COMPARISON TO OTHER RAW
MATERIALS
USING SPENT CATALYSTS AS RAW MATERIALS TO PRODUCE OTHER VALUABLE PRODUCTS
CHALLENGES FACING THE CATALYST REGENERATION INDUSTRY
SPENT CATALYST METAL REFINERS’ ISSUES
REGENERATION/METAL RECOVERY/DISPOSAL ECONOMICS
A CHANGING CATALYST INDUSTRY AND MARKETS IN TRANSITION
COMMERCIAL EXPERIENCE WITH REGENERATED CATALYST PERFORMANCE
REGENERATED CATALYST INDUSTRY CONCENTRATED STRUCTURE
MARKET DIFFERENTIATION/SEGMENTATION
COMPETITIVE RATES ROR THE CATALYST REGENERATION INDUSTRY
MERGERS, ACQUISITIONS, DIVESTITURES AND ALLIANCES
GLOBAL DEMAND FOR CATALYST REGENERATION BY REGION
MAJOR TRENDS IMPACTING THE CATALYST REGENERATION BUSINESS
COMPANY MARKET CAPITALIZATION AND KEY PERFORMANCE INDICATORS
CATALYST REGENERATION INDUSTRY MARKET DRIVERS AND THREATS
MARKET LEADERS IN CATALYST REGENERATION INSTRUMENTATION AND SOFTWARE
COMPONENTS
INSTRUMENTATION AND CONTROL COMPONENTS (FLOW METERS, FLOW COMPUTERS,
FLOW INDICATORS, ANALYZERS, DETECTORS, SENSORS AND VALVES)
COMPANY RESULTS

Chapter- 6: COST REDUCTION AND CATALYST REGENERATION MANAGEMENT
STRATEGY
INTRODUCTION
BUSINESS CASE: CATALYST REGENERATION
DEMAND BY TYPE OF CATALYST REGENERATION MANAGEMENT ACTIVITY
DEMAND BY CATALYST REGENERATION TYPE
Table 78 : GLOBAL MAKRET FORECAST DEMAND FOR SPENT CATALYST
REGENERATION TYPE, THROUGH 2010

Chapter- 7: DEMAND BY PRODUCT
INTRODUCTION
DEMAND BY PRODUCT

Chapter- 8: DEMAND BY APPLICATION
INTRODUCTION
Table 83 : GLOBAL MARKET FORECAST FOR REGENERATED CATALYSTS BY SECTOR,
THROUGH 2010

Chapter- 9: TECHNOLOGY
INTRODUCTION
CATALYST MANAGEMENT TECHNOLOGY
SPENT CATALYST REGENERATION TECHNOLOGY
SPENT AND REGENERATED CATALYST EVALUATION AND CHARACTERIZATION
TECHNOLOGY
DEMAND FOR CATALYST REGENERATION BY CONTAMINATION AND POISON TYPE
DEMAND FOR CATALYST REGENERATION BY COMMERCIAL SPENT CATALYST GENERATION
REACTION AND REACTOR
DEMAND FOR CATALYST REGENERATION BY SITE/METHOD TECHNOLOGY
DEMAND FOR CATALYST REGENERATION BY MATERIAL TECHNOLOGY
DEMAND FOR REGENERATED CATALYSTS BY DEPLOYMENT TECHNOLOGY
TECHNOECONOMICS OF SPENT CATALYST REGENERATION
CATALYST REGENERATION TECHNOLOGY HEALTH AND SAFETY ASPECTS
CATALYST REGENERATION TECHNOLOGY DEVELOPMENT
CATALYST REGENERATION PRODUCT DEVELOPMENT AND IMPORTANT APPROACHES
CATALYST REGENERATION PROCESSES AND APPLICATIONS
NEW TECHNOLOGIES
INVESTMENT BY A MAJOR CATALYST REGENERATION COMPANY
PATENT EVALUATION AND MAJOR DEVELOPMENTS IN CATALYST RESEARCH AND
DEVELOPMENTS ALONG THE S-CURVE
RESEARCH AND DEVELOPMENT LEADERS
Chapter- 10: COMPANY PROFILES
SPENT CATALYST REGENERATION, RECYCLING AND REACTOR MANAGEMENT
WASTE MANAGEMENT SERVICES AND PRODUCTS
FLOW METERS, FLOW COMPUTERS AND FLOW INDICATORS
CATALYST REGENERATION INSTRUMENTATION AND CONTROL COMPONENTS
POWER GENERATORS

List of Tables

Summary Table : GLOBAL MARKET FORECAST FOR CATALYST REGENERATION BY SITE
TECHNOLOGY, THROUGH 2010
Table 1 : GLOBAL MARKET FORECAST DEMAND FOR CATALYSTS, THROUGH 2010
Table 2 : GLOBAL MARKET FORECAST FOR REGENERATED CATALYSTS AS A PERCENTAGE
OF TOTAL CATALYST DEMAND, THROUGH 2010
Table 3 : COST OF FRESH AND REGENERATED CATALYSTS
Table 4 : GLOBAL MARKET FORECAST FOR COST OF SPENT CATALYST USE BY OPTION,
THROUGH 2010
Table 5 : OVERVIEW OF SERVICES VALUE IN CATALYST MANAGEMENT ACTIVITY
Table 6 : OVERVIEW OF REGENERATED CATALYST CHARACTERISTICS AND PROPERTIES
Table 7 : PREBURNING IMPROVES SAMPLING ACCURACY
Table 8 : TYPICAL CATALYST DATA REPORT
Table 9 : GLOBAL MARKET FORECAST OVERVIEW OF REGENERATED CATALYST DEMAND BY
ECONOMIC SECTOR, THROUGH 2010
Table 10 : GLOBAL MARKET FORECAST OF ENERGY CONSUMPTION BY FUEL TYPE,
THROUGH 2010
Table 11 : OVERVIEW OF WORLD KEY ECONOMIC INDICATORS, 2002-2010
Table 12 : OVERVIEW OF WORLDWIDE GDP AND GDP GROWTH
Table 13 : OVERVIEW OF INTERNATIONAL CURRENCY EXCHANGE RATES, THROUGH 2005
Table 14 : OVERVIEW OF NICKEL AND STEEL METAL PRICES
Table 15 : ALUMINUM, COBALT, COPPER, ZINC, TIN, CHROMIUM AND MOLYBDENUM METAL
PRICE FORECASTS*, THROUGH 2005
Table 16 : PLATINUM GROUP METAL PRICE FORECASTS, THROUGH 2005
Table 17 : OPERATING COST INDEX FOR HF AND H2SO4, THROUGH 2005
Table 18 : COST OF RARE EARTHS AND MAGNESIUM, THROUGH 2005
Table 19 : COMPARISON OF SPENT CATALYSTS FROM VARIOUS SOURCES
Table 20 : SIGNIFICANCE OF CATALYST PHYSICAL PROPERTIES
Table 21 : OVERVIEW OF THE CAUSE AND EFFECT OF CATALYST ACTIVITY DETERIORATION
Table 22 : CATALYST REGENATION: ADVANTAGES AND DISADVANTAGES
Table 23 : SULFUR LIMITS IN SELECT COUNTRIES
Table 24 : THE EVOLUTION OF AUTO EMISSION STANDARDS IN THE U.S.
Table 25 : GLOBAL MARKET FORECAST FOR REGENERATED CATALYST REGION/MARKET BY
SEGMENT, THROUGH 2010
Table 26 : SECTOR/PRODUCT MATRIX
Table 27 : OVERVIEW OF GLOBAL DEMAND FOR CATALYST REGENERATION BY REGION,
THROUGH 2005
Table 28 : CHARACTERISTICS OF FRESH, SPENT AND REGENERATED CATALYSTS
Table 29 : CHEMICAL COMPOSITION (WT %) OF SPENT CATALYST AND OTHER RAW
MATERIALS
Table 30 : COMPOSITION OF SPENT NICKEL CATALYSTS USED IN HYDROGENATION OF
EDIBLE FATS AND OILS
Table 31 : COMPRESSIVE STRENGTH OF CONCRETE CUBES PREPARED FROM SYNTHETIC
AND NATURAL AGGREGATES
Table 32 : TYPICAL PILOT PLANT TEST SUMMARY
Table 33 : GLOBAL MARKET FORECAST FOR SPENT CATALYST REGENERATION/METAL
RECOVERY/DISPOSAL ECONOMICS, THROUGH 2010
Table 34 : REGENERATED CATALYST RESALE ECONOMICS
Table 35 : A CHANGING CATALYST INDUSTRY MARKET STRUCTURE
Table 36 : SUPPLIER OFFERINGS (2005)
Table 37 : CATALYST OPERATING CONDITIONS
Table 38 : LABORATORY TEST RESULTS
Table 39 : SUMMARY OF SCOPE OF WORK
Table 40 : TEST CONDITIONS FOR REGENERATED SCR CATALYST
Table 41 : PRODUCT PERFORMANCE OBTAINED
Table 42 : CATALYST REGENERATION INDUSTRY CONCENTRATION BY
COMPANY/APPLICATION SECTOR, 2005
Table 43 : MARKET LEADERSHIP BY GEOGRAPHIC REGION, 2005
Table 44 : COMPANY CATALYST REGENERATION SEGMENTATION BY SERVICE, 2005
Table 45 : JOHNSON MATTHEY REFINING CATALYST RESIDUE AND METAL MANAGEMENT
SERVICES
Table 46 : MOST FREQUENTLY REQUESTED TOTAL CATALYST MANAGEMENT SERVICES
Table 47 : CATALYST REGENERATION SEGMENTATION BY TECHNOLOGY, 2005
Table 48 : COMPETITIVE RATES FOR THE CATALYST REGENERATION INDUSTRY
Table 49 : CORPORATE MERGERS AND ACQUISITIONS
Table 50 : GLOBAL MARKET FORECAST OF DEMAND FOR CATALYTS REGENERATION BY
REGION, THROUGH 2010
Table 51 : NORTH AMERICAN MARKET FORECAST FOR THE REGENERATED CATALYST
MARKET BY SECTOR, THROUGH 2010
Table 52 : EUROPEAN MARKET FORECAST FOR DEMAND FOR REGENERATED CATALYSTS BY
USE, THROUGH 2010
Table 53 : ASIAN MARKET FORECAST DEMAND FOR REGENERATED CATALYSTS BY USE,
THROUGH 2010
Table 54 : R-O-W MARKET FORECAST DEMAND FOR REGENERATED CATALYSTS BY USE,
THROUGH 2010
Table 55 : REST-OF-WORLD MARKET FORECAST DEMAND FOR REGENERATED CATALYSTS
BY TYPE, THROUGH 2010
Table 56 : GLOBAL CASH OPERATING MARGINS IN CRUDE OIL REFINING, 2005
Table 57 : TRENDS IN CRUDE OIL REFINING MARGINS
Table 58 : TRENDS IN CRUDE OIL QUALITY PROCESSED IN U.S. REFINERIES, THROUGH
2001
Table 59 : GLOBAL REFINERY CAPACITY TRENDS
Table 60 : CATALYST REGENERATION TRENDS, THROUGH 2000
Table 61 : TRENDS IN AVERAGE ANNUAL PRICES1 OF SELECTED METALS, 1994-2001
Table 62 : SPENT AUTOCATALYST METAL RECOVERY TRENDS
Table 63 : GLOBAL POWER PLANT MARKET SHARE TRENDS BY REGION*
Table 64 : GLOBAL POWER PLANT MARKET SHARE TRENDS BY FACILITY TYPE*
Table 65 : CATALYST COMPANY MARKET CAPITALIZATION AND KEY PERFORMANCE
INDICATORS, 2005
Table 66 : PETROLEUM REFINING COMPANY MARKET CAPITALIZATION AND KEY
PERFORMANCE INDICATORS, 2005
Table 67 : CHEMICAL AND POLYMERIZATION COMPANY MARKET CAPITALIZATION AND KEY
PERFORMANCE INDICATORS, 2005
Table 68 : POWER GENERATION COMPANY MARKET CAPITALIZATION AND KEY
PERFORMANCE INDICATORS, 2005
Table 69 : AUTOMOTIVE COMPANY MARKET CAPITALIZATION AND KEY PERFORMANCE
INDICATORS, 2005
Table 70 : ULTRA-LOW SULFUR DIESEL COMMERCIAL UNITS
Table 71 : CONSTRUCTION OF ULTRA-LOW SULFUR DIESEL REFINERIES
Table 72 : MARKET LEADERS IN INSTRUMENTATION AND CONTROL COMPONENTS, 2004
Table 73 : MARKET LEADERS IN SOFTWARE COMPONENTS FOR CATALYST REGENERATION,
2004
Table 74 : COMPANY RESULTS
Table 75 : COST COMPARISON: REGENERATION VS. BUYING NEW CATALYST
Table 76 : WAYS TO MEASURE CATALYTIC ACTIVITY AND POTENTIAL
Table 77 : DEMAND FOR CATALYST REGENERATION MANAGEMENT BY SERVICE
Table 78 : GLOBAL MAKRET FORECAST DEMAND FOR SPENT CATALYST REGENERATION
TYPE, THROUGH 2010
Table 79 : GLOBAL MARKET FORECAST DEMAND FOR STANDARD CATALYST
REGENERATION BY OPERATION, THROUGH 2010
Table 80 : GLOBAL MARKET FORECAST DEMAND FOR TURNAROUND CATALYST
REGENERATION BY OPERATION, THROUGH 2010
Table 81 : DEMAND FOR PRERECLAMATION CATALYST REGENERATION BY OPERATION.
THROUGH 2010
Table 82 : GLOBAL FORECAST OF DEMAND FOR REGENERATED CATALYSTS BY PRODUCT,
THROUGH 2010
Table 83 : GLOBAL MARKET FORECAST FOR REGENERATED CATALYSTS BY SECTOR,
THROUGH 2010
Table 84 : GLOBAL MARKET FORECAST FOR CATALTIC REFINERY PROCESSING CAPACITY,
THROUGH 2010
Table 85 : GLOBAL MARKET FORECAST DEMAND FOR CATALYST REGENERATION IN CRUDE
OIL REFINING BY PROCESS, THROUGH 2010
Table 86 : GLOBAL MARKET FORECAST FOR CATALYTIC HYDROTREATING DEMAND FOR
REGENERATED CATALYSTS BY DEPLOYMENT, THROUGH 2010
Table 87 : CONVENTIONAL AND IMPROVED HYDROTREATING AND HYDROPROCESSING
CATALYSTS FOR DIESEL PRODUCTION
Table 88 : FCC DEMAND FOR REGENERATED CATALYSTS BY DEPLOYMENT, THROUGH 2010
Table 89 : CONVENTIONAL AND IMPROVED FCC CATALYSTS FOR GASOLINE PRODUCTION
Table 90 : GLOBAL MARKET FORECAST FOR CATALYTIC REFORMING DEMAND FOR
REGENERATED CATALYSTS, THROUGH 2010
Table 91 : CONVENTIONAL AND IMPROVED REFORMING CATALYSTS FOR GASOLINE
PRODUCTION
Table 92 : GLOBAL MARKET FORECAST FOR CATALYTIC HYDROCRACKING DEMAND FOR
REGENERATED CATALYSTS BY DEPLOYMENT, THROUGH 2010
Table 93 : CONVENTIONAL AND IMPROVED HYDROCRACKING CATALYSTS FOR RESIDUE
CONVERSION AND LOW-SULFUR FUEL OIL PRODUCTION
Table 94 : GLOBAL MARKET FORECAST DEMAND FOR REGENERATED CATALYSTS BY
ALKYLATION AND ISOMERIZATION, THROUGH 2010
Table 95 : CONVENTIONAL AND IMPROVED ALKYLATION AND ISOMERIZATION CATALYSTS
FOR GASOLINE PRODUCTION
Table 96 : GLOBAL MARKET FORECAST DEMAND FOR REGENERATION CATALYSTS BY
CHEMICAL, THROUGH 2010
Table 97 : EXAMPLES OF CATALYTIC HYDROGENATIONS IN CHEMICALS AND
PETROCHEMICALS USING BASE AND PRECIOUS METAL CATALYSTS
Table 98 : GLOBLA MARKET FORECAST DEMAND FOR REGENERATION CATALYSTS BY
CHEMICAL SYNTHESIS TYPE, THROUGH 2010
Table 99 : GLOBAL MARKET FORECAST DEMAND FOR REGENERATION CATALYSTS BY
POLYMERIZATION TYPE, THROUGH 2010
Table 100 : GLOBAL MARKET FORECAST DEMAND FOR SPENT AUTOCATALYST
PRERECLAMATION REGENERATION BY METAL TYPE, THROUGH 2010
Table 101 : GLOBAL MARKET FORECAST DEMAND FOR FLUE GAS AND WASTE CATALYST
SUPPLY BY PROCESS, THROUGH 2010
Table 102 : GLOBAL MARKET FORECAST FOR REGENERATED CATALYST MANAGEMENT BY
ACTIVITY COST, THROUGH 2010
Table 103 : TYPICAL CATALYST MANAGEMENT
Table 104 : SCR CATALYST MANAGEMENT
Table 105 : MEASURES TO LIMIT COKE FORMATION IN VARIOUS REACTOR TYPES
Table 106 : CHARACTERIZATION OF SPENT EBZ-500 AS RECEIVED AND AFTER
LABORATORY REGENERATION
Table 107 : MASS BALANCE OF THE COMMERCIAL REGENERATION OF A TWO-BED
REACTOR OF EBZ-500 CATALYST UNLOADED FROM A EUROPEAN UNIT
Table 108 : ANALYSIS OF SPENT, LABORATORY AND INDUSTRIALLY REGENERATED
CATALYST
Table 109 : PERFORMANCE OF FRESH AND REGENERATED EBZ-500 CATALYST IN THE
COMMERCIAL UNIT
Table 110 : EXPERIMENTAL PROCEDURE FOR H2-CHEMISORPTION MEASUREMENTS
Table 111 : COMPARISON OF TEST GAS MIXTURE FOR ACTIVITY MEASUREMENTS
Table 112 : GLOBAL MARKET FORECAST FOR CATALYST REGENERATION BY DEACTIVATION
TECHNOLOGY, THROUGH 2010
Table 113 : GLOBAL MARKET FORECAST DEMAND FOR CATALYST REGENERATION BY TYPE
OF COMMERCIAL SPENT CATALYST GENERATION REACTION, THROUGH 2010
Table 114 : COMMERCIAL SPENT CATALYST GENERATION GAS-PHASE
REACTIONS/REACTORS
Table 115 : GLOBAL MARKET FORECAST DEMAND FOR CATALYST REGENERATION IN GAS-
PHASE REACTION BY COMMERCIAL SPENT CATALYST GENERATION REACTORS, THROUGH
2010
Table 116 : COMMERCIAL SPENT-CATALYST GENERATION GAS-LIQUID REACTIONS AND
REACTORS
Table 117 : GLOBAL MARKET FORECAST DEMAND FOR CATALYST REGENERATION IN GAS-
LIQUID REACTION BY COMMERCIAL SPENT CATALYST GENERATION REACTORS, THROUGH
2010
Table 118 : GLOBAL MARKET FORECAST DEMAND FOR CATALYST REGENERATION IN
LIQUID-LIQUID REACTION BY COMMERCIAL SPENT CATALYST GENERATION REACTORS,
THROUGH 2010
Table 119 : GLOBAL MARKET FORECAST FOR CATALYST REGENERATION DEMAND BY SITE
TECHNOLOGY, THROUGH 2010
Table 120 : GLOBAL MARKET FORECAST DEMAND FOR OFF-SITE CATALYST REGENERATION
BY PROCESS TECHNOLOGY, THROUGH 2010
Table 121 : ON-SITE CATALYST REGENERATION TECHNOLOGY
Table 122 : GLOBAL MARKET FORECAST DEMAND FOR ON-SITE SPENT CATALYST
REGENERATION BY PROCESS TECHNOLOGY, THROUGH 2010
Table 123 : GLOBAL MARKET FORECAST DEMAND FOR REGENERATED CATALYST BY
MATERIAL TECHNOLOGY, THROUGH 2010
Table 124 : GLOBAL MARKET FORECAST DEMAND FOR REGENERATED CATALYSTS BY
DEPLOYMENT TECHNOLOGY, THROUGH 2010
Table 125 : GLOBAL MARKET SHARE FOR CATALYST REPLACEMENT COST ESTIMATE, 2002-
2010
Table 126 : GLOBAL MARKET SHARE FOR CATALYST REGENERATION COST ESTIMATE,
2002-2010
Table 127 : MODEL CALCULATION VALUES
Table 128 : OPERATING COSTS
Table 129 : SELECTED SAFETY CHARACTERISTICS OF VARIOUS PRODUCTS
Table 130 : TECHNOLOGY DEVELOPMENT
Table 131 : PRODUCT DEVELOPMENT AND IMPORTANT APPROACHES
Table 132 : PROCESSES AND APPLICATIONS
Table 133 : FEEDSTOCK EFFECTS
Table 134 : INVESTMENTS MADE BY MAJOR CATALYST REGENERATION COMPANIES,
THROUGH 2005
Table 135 : PATENTS BY MAJOR R&D CATALYST COMPANY
Table 136 : RESEARCH AND DEVELOPMENT SPENDING BY COMPANY, THROUGH 2005

List of Figures
Summary Figure : GLOBAL MARKET FORECAST FOR CATALYST REGENERATION BY SITE
TECHNOLOGY, 2002-2010
Summary Figure : BET equation
Figure 1 : ROTO-LOUVRE CATALYST REGENERATION TECHNOLOGY
Figure 2 : MOVING-BELT OVEN EX SITU CATALYST REGENERATION PROCESS
Figure 3 : SCR REGENERATION STRATEGIES
Figure 4 : SCR-TECH CATALYST REGENERATION DEVELOPMENT, 1996-2004
Figure 5 : SCR-TECH REGENERATION EXPERIENCE
Figure 6 : RHENIUM METAL PRICES
Figure 7 : AGEING-INDUCED STRUCTURAL AND CHEMICAL CHANGES IN AUTOMOTIVE
EXHAUST CATALYST
Figure 8 : QUARTELY FOREIGN GROSS REFINING MARGINS, 2002-2005
Figure 9 : STRUCTURE AND SUPPLY CHAIN OF THE CATALYST REGENERATION BUSINESS
Figure 10 : TYPICAL LABORATORY SPENT CATALYST REGENERATION/REJUVENATION
PROCESS FLOW DIAGRAM
Figure 11 : COMPARISON OF SPENT AND REGENERATED CATALYST PERFORMANCE
Figure 12 : ACTIVITY (K) IN COMPARISON TO FACTORY NEW ACTIVITY (K0) BEFORE AND
AFTER REGENERATION (SAMPLES)
Figure 13 : EFFECT OF FIRING TEMPERATURES ON METALS LEACHING FROM SYNTHETIC
AGGREGATE MATERIALS
Figure 14 : EFFECT OF FIRING TEMPERATURES ON COMPRESSIVE STRENGTH OF
SYNTHETIC AGGREGATE MATERIALS
Figure 15 : CHALLENGES FACING KEY PLAYERS IN THE CATALYST REGENERATION
BUSINESS CHAIN
Figure 16 : PERFORMANCE OF REGENERATED KF 757 VS. FRESH KF 757: CUSTOMER A
Figure 17 : PERFORMANCE OF REGENERATED KF 757 VS. FRESH AND REGENERATED KF
756: CUSTOMER B
Figure 18 : PERFORMANCE OF REGENERATED KF 757 VS FRESH KF 757 AND REGENERATED
KF 756: CUSTOMER C
Figure 19 : PERFORMANCE OF REGENERATED KF 757 VS FRESH KF 757: CUSTOMER D
Figure 20 : HISTORY OF BHK ACTIVITY IN SCR CATALYST REGENERATION
Figure 21 : REGENERATION SCHEDULE
Figure 22 : SCR-TECH CATALYST REGENERATION MANAGEMENT SERVICES
Figure 23 : THE PRECIOUS METAL LOOP
Figure 24 : COMPLETED CATALYST MANAGEMENT PROJECTS, 1998-2003
Figure 25 : THE TRICAT XPRESS REGENERATION PROCESS
Figure 26 : EURECAT ROTOLOUVRE REGENERATION TECHNOLOGY
Figure 27 : MOVING-BELT CATALYST REGENERATION PROCESS
Figure 28 : AN EFFCIENT DEIONIZED WATER-BASED, CLOSED-LOOP SYSTEM FOR REMOVAL
OF SOLUBLE CATALYST POISONS AND SURFACE-BINDING LAYERS WHILE CATALYST
MODULES REMAIN IN THE SCR REACTOR
Figure 29 : JOHNSON MATTHEY AQUACAT PROCESS FOR RECOVERY OF PRECIOUS METAL
CATALYSTS
Figure 30 : BABCOCK HITACHI K.K. REGENERATION PROCESS
Figure 31 : WORLD TRENDS IN NOMINAL CRUDE OIL PRICES, 1970-2005
Figure 32 : BETTER THAN NEW
Figure 33 : COMPARED TO NEW CATALYST, REGENERATED CATALYST CONVERTS LESS
SULFUR DIOXIDE (SO2) TO SULFURE TRIOXIDE (SO3)
Figure 34 : AN OPTIMIZED CATALYST MANAGEMENT PROCESS TAKES INTO ACCOUNT
MORE VARIABLES THAN MIGHT BE EXPECTED
Figure 35 : STEPS IN CATALYST MANAGEMENT INVOLVING THE OPTIMIZATION OF A WIDE
RANGE OF PARAMETERS
Figure 36 : CATALYST MANAGEMENT PLAN SHOWING PARAMETERS
Figure 37 : MULTIPOINT AUTOMATED SAMPLING SYSTEM (MASS) USED FOR AMMONIA
INJECTION GRID TURNING
Figure 38 : DRY CLEANING USING VACUUMING/AIR LANCING CAN REPLACE CATALYST
FOULING DUE TO BUILDUP OF LARGE PARTICLE ASH AND ASH FINES
Figure 39 : ASH REMOVAL
Figure 40 : VACUUMING
Figure 41 : WASHING WITH A CLEANING SOLUTION
Figure 42 : BUBBLING AND AERATION UNDER PRESSURE
Figure 43 : AKZO NOBEL CATALYST MANAGEMENT STRATEGIES
Figure 44 : EURECAT CATALYST MANAGEMENT STRATEGIES
Figure 45 : TYPICAL SCR CATALYST MANAGEMENT PLAN
Figure 46 : SCHEMATIC OF PRECIOUS METAL RECOVERY FROM SPENT CATALYSTS
Figure 47 : NORMAL ADD AND REPLACE SEQUENCE
Figure 48 : ATALYST REGENERATION SEQUENCE
Figure 49 : EXPERIMENTAL SETUPS FOR NO-TPD MEASUREMENTS IN A VACUUM
Figure 50 : X-RAY DIFFRACTOMETER SCHEMATIC
Figure 51 : XPS MACHINE SCHEMATIC
Figure 52 : X-RAY FLUORESCENCE SPECTROMETER SCHEMATIC
Figure 53 : EXPERIMENTAL SETUPS FOR ACTIVITY MEASUREMENTS
Figure 54 : DEACTIVATION MECHANISMS: A) COKE FORMATION, B) POISONING, C)
SINTERING OF ACTIVE METAL PARTICLES AND D) SINTERING AND SOLID-SOLID PHASE
TRANSITIONS OF THE WASHCOAT AND ENCAPSULATION OF ACTIVE METAL PARTICLES
Figure 55 : CATALYST REGENEATION SOLUTIONS TO THE PROBLEM OF RAPIDLY
DEACTIVATING CATALYSTS IN COMMERCIAL REACTOR SYSTEMS
Figure 56 : CONCEPTURAL DSRP INTEGRATED WITH HOT COAL GAS DESULFURIZATION
Figure 57 : MAJOR DEVELOPMENTS IN CATALYST RESEARCH AND DEVELOPMENTS ALONG
THE S-CURVE
Figure 58 : DIESEL OXIDATION FILTER

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DOCUMENT INFO
Description: This BCC Research study focuses on the catalyst regeneration business. Global value demand for catalysts (both fresh and regenerated) will grow 7.9% yearly from the current value of $11.5 billion to $16.9 billion through 2010. This is based on increased production of end-use products and a shift toward higher-value catalyst materials. Polymerization catalysts will grow the fastest while chemical synthesis catalysts will surpass petroleum refining types as the largest segment.