PolyMax 600 catalysts are used in PP production |
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Incremental improvements to the catalyst design , by optimising its shape , have already optimised the process . To achieve breakthrough innovation means new reactor and catalyst designs . EARTH , it is claimed , is such a breakthrough in both respects . “ Currently , reformer reactors consist of a number of tubes operating in parallel and in those tubes , catalysts are loaded and form a fixed bed ,” said Estenfelder . “ EARTH technology is based on a series of tube-in-tube compartments , in which a thinner tube is positioned centrally inside a larger one . This forms an annular gap in which the new catalyst is positioned .” The new catalyst consists of a structured support made from a thin metal blade , with the active element wash-coated onto it . By positioning it in the tube-in-tube concept , it can be heated through both the outer and inner boundary tubes . In a first commercial reference project with a small reformer , Estenfelder said , the technology achieved fuel savings of 38 % thanks to an efficient internal heat recovery enabled by a catalyst with a maximised surface area , 20 % lower CO 2 emissions and a lower pressure drop of 40 %. “ These figures |
are quite remarkable per se , and even more so if you remember that this an already highly optimised technology .”
PolyMax 600
Addressing the dimension safer chemicals is the new PolyMax 600 series of catalysts for polypropylene ( PP ) production . This was developed in response to the growing concern over toxic substances . The Clariant Catalysts R & D team was charged with creating a catalyst that did not contain phthalates . Consumer and medical brand owners , themselves under pressure from consumers and regulators , want to switch to phthalate-free resins . And the catalysts used in PP production are actually consumed and remain in the final product . At present , most contain small amounts of phthalates . “ The phthalates are in there for a reason ,” said Estenfelder . “ Phthalate catalysts enable you to make PP with good mechanical and physical properties , like stiffness and impact resistance . The challenge is not just to take out the phthalate but to make a polymer with the same properties .” This is a major hurdle to overcome , he said . The results in commercial
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tests of PolyMax 600 , however , have “ exceeded expectations ”. The polymers produced are not only phthalate-free but unexpectedly also had superior impact resistance and stiffness , according to the unnamed customer who evaluated these catalysts . The process also improved productivity in the customer ’ s plant in a way that translated into $ 8 million / year of additional output . “ This is a particularly nice example , because we started with a challenge coming from an environmental and health perspective and we turned it into a technical and finally a business opportunity ,” said Estenfelder .
Hydex E
Hydex E , a dewaxing catalyst used to derive high-value diesel fuel from plastic waste , addresses the topic of circularity ( Figure 1 ), Estenfelder continued . There is a clear need for this , given that 87 % of the 350 million tonnes / year of plastics produced now are still derived from virgin liquid feedstock , as against 12 % from mechanical recyclates and less than 1 % from pyrolysis . Major consumer goods producers aim to increase recycled content in use by 25-50 % by 2025 and nearly 60 % of all polymers – by then totalling 1.31
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JAN / FEB 2021 |
37 |