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:
