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

Divisional structure

Emission Control
Technologies

Process
Technologies

Precious Metal
Products

Light Duty Catalysts

Chemicals

Services

Heavy Duty Catalysts

Syngas

Stationary Emissions
Control

Johnson Matthey
Davy Technologies

Chemical Catalysts
(including Formox)

Oil and Gas

Refineries

Purification

Tracerco

Fine
Chemicals

Active Pharmaceutical
Ingredient (API)
Manufacturing

New Business
Development

Water

Catalysis and Chiral

Technologies

Battery Technologies

Research Chemicals

Fuel Cells

Platinum Marketing
and Distribution
Refining

Manufacturing

Noble Metals

Colour Technologies

Chemical Products

New
Businesses

History of process technologies

JM pgm
catalysts

ICI Synetix

Intercat

Base metal
catalysts

Additives for
FCC applications

2002

2006

Davy Process
Technology
Process technologies,
process
engineering and licensing

2010

2013

Process
Technology
Division

Formox
Formaldehyde
catalysts,
licences and
technologies
4

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

Billingham Concept - 1920

11

1940s ICI Reforming technology development

14

Early 1960s reforming flowsheet

15

Steam Reforming process licencing

16

Mid -1960s ICI-patented LTS

17

1960s Technology development continues

3 of worlds 1st 1,000 stpd Kellogg
plants, establishing the modern
flowsheet

18

1970s ICI HAZOP process

19

1980s Process Developments

LCA small scale process

AMV low energy process

20

1990s Specialisation
The two industry founders chose their futures
BASF focuses on speciality chemicals and its
integrated chemicals manufacturing sites
Sells its 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

21

Heritage Plants Operated by ICI

Plant

Country

Design

Severnside 1
Severnside 1A
Billingham 1
Billingham 2
Billingham 3
Courtright 1
Immingham
Kanpur 1
Kanpur 2
Gibson Island
Newcastle
Billingham 4
Modderfontein
Cork
Kanpur 3
Courtright 2
Severnside LCA 1
Severnside LCA 2

UK
UK
UK
UK
UK
Canada
UK
India
India
Australia
Australia
UK
S Africa
Eire
India
Canada
UK
UK

ICI
Bechtel
Kellogg
Kellogg
Kellogg
Kellogg
Kellogg
India
India
Pritchard
Kellogg
Jacobs
Kellogg
Kellogg
India
ICI
ICI
UK

Capacity,
Te/day
300
570
900
900
900
900
570
415
415
540
540
1100
1100
1350
415
1100
450
450

Start-up
1962
1965
1966
1966
1967
1967
1967
1969
1969
1969
1969
1977
1978
1979
1981
1985
1988
1988

Technology Alliances
TKIS (Uhde) Worlds leading Ammonia contractor
Catalyst & technology agreement since 1998
Joint technology development, including TKISs Dual
Pressure Process for 3,300TPD plants
Stronger technical support to Uhde & Uhde customer
Revamp capabilities, catalyst and engineering
Davy Worlds leading Methanol process contractor
Own roots in the syngas industry (Davy Powergas)
Technology / Supply agreements since 1960s
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

Maaden

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

1960s - 2002

Catalyst manufacturing
started.
First methanol syn catalyst.
Focus on own (ICI) plants.

Upgraded for commercial

catalysts.
Expansion of range to cover
all syngas and others.
Steady growth in capacity,
new products

2002 2008

2008 - 2015

Accelerated investment
under JM.
Investment in reforming,
GTL, shift.

Significant investment &

expansion.
Methanol syn, reforming,
Substitute Natural Gas,
purification

28

JM Catalyst Manufacture in India

Catalyst manufacture in India

1984

1994 2002

2002 2009

2009-2015

Catalyst manufacturing
started.
Integrated with fertilizer
plant.

Separated from fertilizer

plant.
Own Infrastructure.
Independent
operations.

Investment under JM.

Purification expansion.
Plant automation &
uprating.

Significant investment
& expansion.
Reforming, prereforming, purification

30

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

31

JM heritage core to the ammonia industry

33

Johnson Matthey our future

In 2017 JM enters its 3rd Century
Our strategy that will take us into our 3rd Century of valueadding sustainable technologies is summarized by:
The 3Cs: