Workshop - Forskningsinfrastruktur för industriella innovationer, 14 June 2012, Stockholm             Key challenges for i...
Topsøe Group’s headquarters    in Lyngby, Denmark   Established 1940   Ownership: Haldor Topsøe Holding A/S (100%)   An...
Our business areas …founded in heterogeneous catalysis Fertiliser industry (ammonia, …) Heavy chemical and petrochemical...
Global Challenges        World population          – Food shortage        Resources          – Efficient use of resource...
Goals in Catalysis  Understand and predict relation between material properties and   reactivity  Towards a rational des...
What type of RI does industry need?    Type of industrial use of RI’s:     mainly strategic R&D     (not basic research, ...
In situ techniques in catalysis                       Reactants - Gas control system    Relate Structure                  ...
Ammonia Synthesis Catalyst N2(g) + 3 H2(g) → 2 NH3(g)  Fe/FeO-catalyst  1 kg of catalyst → 25 tonnes of NH3  Annual pro...
World Population                                                        100                              6                ...
Recent industrial refinery catalysts  Haldor Topsøe has introduced new generations of   hydrotreating catalysts  Aided b...
New In Situ Techniques Provided Insight     First in situ EXAFS                                  Mo present as            ...
New In Situ Techniques Provided Insight     First in situ EXAFS                                  Mo present as            ...
Do we get what we need?YES, but …
Key challenges for industrial use of RI’s - 1  Large expenses, large distance    – travel, hotel, beamtime, equipment  M...
Key challenges for industrial use of RI’s - 2  Differences with academic use of large-scale facilities:    – Industry: la...
Increase of industrial use of SR   Short access time to beamlines (2-4 weeks), preferably at short    distance from home ...
Thank you for your attentionCatalyzing your business
Future possibilities for industrial use of RI’s  Imaging:     – Nano-tomography including element mapping as       comple...
Use of RIs at Haldor Topsøe A/S:   Since 1981 (synchrotron):    About 3 refereed publications by HTA/S authors per year  ...
Topsøe   - A global supplier of catalysts and technologies                                                        Headquar...
… and a leading market player Market share between 15-25% for established products Supplier of solutions for 50% of new ...
Topsøe is dedicated to… Research and development in heterogeneous catalysis Production and sale of catalysts Licensing ...
Research– for process and catalyst development                                                       300 employees in R&D...
Catalysts Catalyst production and supply Loading/start-up assistance to  operators                                    T...
Catalysing your business
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TOPSOE - Key challenges for industrial use of research infrastructure

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PowerPoint från "Forskningsinfrastruktur för industriella innovationer". Workshopen ägde rum i juni 2012 och anordnades av Vetenskapsrådet, VINNOVA, Industrirådet och RISE. Mer information: http://bit.ly/Mxezmv

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  • I’m a general manager at the privately owned company Haldor Topsøe with headquarters just north from Copenhagen in Denmark. We produce catalysts and technology based on heterogeneous catalysis and have a strong effort in R&D. Last year’s turnover was about 600 miljon Euro and we are about 2200 people, not only in the Copenhagen area but also in at least 10 other places in the world e.g. production in Houston, Texas en Engineering in New Dehli, India.
  • Our business is in the areas of fertilizer industry where we produce catalysts and technology for ammonia synthesis, all the way starting from natural gas and steam reforming to produce pure hydrogen that can be reacted with N2 to NH3. This process uses 10 different catalysts.
  • One ton of ammonia synthesis catalyst will within its operational life produce ammonia which as fertilizer may produce food for 100 people in 10 years. Topsoe sells 4000 t of ammonia synthesis catalyst per year. The composition of the catalyst has been known for about 100 years. It is the know-how about its function and how to achieve the optimum surface structures during preparation and operation which is the competitive advantage.
  • En grov fortolkning af disse figurer: Indtil industrialiseringen i krigsårene levede der knap 2 mia mennesker, som måske er det antal mennesker, Jorden i sig selv kan holde i live. Men siden krigsårene er vi blevet flere og flere, har passeret 6 mia mennesker og er på vej mod de 10 mia mennesker. Umiddelbart før 1. verdenskrig udvikledes NH3-syntesen til fremstilling af kunstgødning. Dvs denne proces, denne ene kemiske reaktion holder pt 4 mia mennesker i live. Og da HTAS står for mere end halvdelen af katalysatormarkedet, holder vi i HTAS mere end 2 mia mennesker i live! Reel pointe: NH3-syntesen er en vigtig katalytisk proces, som kun vil blive vigtigere i fremtiden.
  • Note reduction in Mo-Mo coordination number for sulfided catalyst, both Mo and CoMo: nano-clusters of MoS2
  • Interpretation from XAFS not unique
  • TOPSOE - Key challenges for industrial use of research infrastructure

    1. 1. Workshop - Forskningsinfrastruktur för industriella innovationer, 14 June 2012, Stockholm Key challenges for industrial use of research infrastructure Alfons Molenbroek am@topsoe.dkHaldor Topsøe A/SCatalyzing your business
    2. 2. Topsøe Group’s headquarters in Lyngby, Denmark Established 1940 Ownership: Haldor Topsøe Holding A/S (100%) Annual turnover (2011): ~600 MM EUR (> 4.46 billion DKK ) Number of employees ~2200
    3. 3. Our business areas …founded in heterogeneous catalysis Fertiliser industry (ammonia, …) Heavy chemical and petrochemical industries (synthesis gas, methanol, hydrogen, …) Refining industry (hydrotreating, hydrocracking) Environmental and power sector (DeNOx, WSA, SNOX) Renewables (e.g. biofuels, biochemicals)
    4. 4. Global Challenges  World population – Food shortage  Resources – Efficient use of resources  Pollution – Reduction of smog, acid rain
    5. 5. Goals in Catalysis  Understand and predict relation between material properties and reactivity  Towards a rational design of catalysts: Improve design and production of existing processes and catalysts and develop new ones  Tailoring of: – selectivity (100%), activity, deactivation, shape, size, mechanical strength, thermal stability, material costs, purity of raw materials  Driving forces: often (environmental) regulations
    6. 6. What type of RI does industry need?  Type of industrial use of RI’s: mainly strategic R&D (not basic research, not quality control)  Different ways: – fully involved in experiments – collaboration with academic world – analytical service (full analytical lab)  Balance between techniques new for synchrotrons (fs methods, high brilliance nano-beams) and established techniques (high flux, robust techniques)
    7. 7. In situ techniques in catalysis Reactants - Gas control system Relate Structure Tomography to Activity XRD under SAXS process conditions Radiation: EXAFS X-rays Light SEM Electrons TEM IR Raman Products - Mass Spectrometer
    8. 8. Ammonia Synthesis Catalyst N2(g) + 3 H2(g) → 2 NH3(g)  Fe/FeO-catalyst  1 kg of catalyst → 25 tonnes of NH3  Annual production: 150*106 tonnes No catalyst? <150 tonnes It is the know-how that counts
    9. 9. World Population 100 6 Annual use of fertilizer (106 tonnes) 10 World population (billions) 80World population (billions) 5 9 4 8 60 7 3 40 6 2 5 20 1 Prediction 4 Prediction (2 children/woman) 0 0 3 1900 1925 1950 1975 0 0 0 0 0 0 0 0 0 199 201 203 205 207 209 211 213 215 Year Year
    10. 10. Recent industrial refinery catalysts  Haldor Topsøe has introduced new generations of hydrotreating catalysts  Aided by the input from molecular-scale research  Named BRIM™ Technology TK-558 BRIM™ (CoMo) and TK-559 BRIM™ (NiMo) for FCC P/T TK-576 BRIM™ (CoMo) for ULSD
    11. 11. New In Situ Techniques Provided Insight First in situ EXAFS Mo present as Studies of CoMo/Al2O3 Catalysts MoS2 nanoclusters Mo Bulk MoS2 S Relative magnitude Sulf. Mo/ In situ FTIR: Al2O3 Monolayers (single MoS2 slabs) Sulf. CoMo/Al2O3 N.Topsøe (1980) 2 4 6 8 10 R(Å) Clausen, Topsøe et. al (1981)
    12. 12. New In Situ Techniques Provided Insight First in situ EXAFS Mo present as Studies of CoMo/Al2O3 Catalysts MoS2 nanoclusters Mo Bulk MoS2 S Relative magnitude Sulf. Mo/ EXAFS: Does not provide Al2O3 a unique 3D structure Interpretation still controversial! Sulf. CoMo/Al2O3 (Clausen; Prins; Breysse;…) 2 4 6 8 10 R(Å) Clausen, Topsøe et. al (1981)
    13. 13. Do we get what we need?YES, but …
    14. 14. Key challenges for industrial use of RI’s - 1  Large expenses, large distance – travel, hotel, beamtime, equipment  Many experienced researchers needed for one experiment – Complex experiments, unique results?, complex data analysis  Peer review system for beamtime applications: – Judged on scientific quality, not on technological quality or industrial relevance  Confidentiality, IPR, secrecy agreements, bureaucracy  Beamline/experimental staff: – Lack of staff: experiments run 24 hours/day, but staff not always available – Lack of experienced staff (short-term contracts)  Full remote control of experiments is hardly possible  Extra facilities, e.g. preparation lab not always available
    15. 15. Key challenges for industrial use of RI’s - 2  Differences with academic use of large-scale facilities: – Industry: larger amount of samples; model vs. real catalysts – Industry: faster results are demanded: robust methods + on-line analysis + fast access to facilities – Trend: reduced time from R&D to market  Industry: product and process oriented RIs: method, instrument/beamline, fundamental understanding oriented  Lack of quality control of beamlines/instruments: – no standard protocols  Lack of automated on-line data analysis and reduction software  Lack of standardization: – Interfaces between beamline and sample environment – Data formats  Limited interest in industrial use by many RI’s
    16. 16. Increase of industrial use of SR  Short access time to beamlines (2-4 weeks), preferably at short distance from home laboratories  Professional and reliable operation of beamlines and synchrotron  State-of-the-art beamline equipment, laboratories (also for sample preparation) and data analysis  Building and operation of beamlines is responsibility of SR sources – industry is willing to pay for beamtime  Beamline staff on long term contracts to improve competent service; basic understanding of catalytical processes performed present at beamline  Coordination of industrial beamtime applications by an ”industrial user office” to ensure use of the proper beamlines + scientific support Partly from: Final declaration at ”Industrieforum In Situ Charakterisierung Katalytischer Prozesse”, Nov. 2003, Hasylab (Bessy, Anka)
    17. 17. Thank you for your attentionCatalyzing your business
    18. 18. Future possibilities for industrial use of RI’s  Imaging: – Nano-tomography including element mapping as complementary method to transmission electron tomography: X-rays have larger penetration depth: in situ studies on < 10 nm length scale  Design of new facilities: – workhorses vs. high brilliance  Improved instrumentation (detectors): – Follow dynamic changes on short (<1ms) time scale e.g. during crystallization and agglomeration of catalysts  New methods and techniques: – Improve sensitivity for surface and active sites  XFEL: – Femtochemistry: Movie of chemical reaction during adsorption and desorption of gasses at a catalyst surface
    19. 19. Use of RIs at Haldor Topsøe A/S:  Since 1981 (synchrotron): About 3 refereed publications by HTA/S authors per year (average): fundamental understanding  Techniques used: XAFS, XRD, X-ray tomography, SAXS, XRF, XPS, XPCS  Synchrotrons used: HASYLAB, ESRF, SLS, ASTRID, MAXLAB  Amount of beam time per year: ~120 shifts (8 hour)
    20. 20. Topsøe - A global supplier of catalysts and technologies Headquarters Topsøe offices Research Production Engineering Sale & Marketing Copenhagen Moscow Alberta Beijing Los Angeles Houston Bahrain New Delhi Kuala Lumpur Rio Buenos Aires Cape TownSubsidiariesHaldor Topsoe, Inc.Haldor Topsøe International A/S, DenmarkHaldor Topsoe India Pvt. Ltd. IndiaZAO Haldor Topsøe, RussiaSubcontinent Ammonia Investment Company ApS (SAICA)Topsoe Fuel Cell A/S, Denmark
    21. 21. … and a leading market player Market share between 15-25% for established products Supplier of solutions for 50% of new ammonia plants built within the last decade More than 60% of ammonia is produced worldwide on Topsøe catalyst Supplier for 40% of catalysts for production of ultra-low sulphur diesel > 30% market share of hydrogen catalysts Many leading environmental technologies 30% market share of FCC pretreatment catalysts 20% market share of hydrocracking catalysts
    22. 22. Topsøe is dedicated to… Research and development in heterogeneous catalysis Production and sale of catalysts Licensing of technology Equipment supply Engineering and construction of plants based on catalytic processes
    23. 23. Research– for process and catalyst development  300 employees in R&D  Topsøe annually applies 10% of gross revenues to support these R&D efforts  R&D is multi-disciplined Basic Research – Fundamental research Fundamental Studies Catalyst Characterisation – Catalyst development – Catalyst manufacturing – Pilot plant studies Industry Catalyst Formulation – Process development Process Development – Process impact studies – Equipment development Scale-up – Computer modelling Pilot Operation Computer Modelling
    24. 24. Catalysts Catalyst production and supply Loading/start-up assistance to operators  Troubleshooting assistance  Analysis of plant operation
    25. 25. Catalysing your business

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