Catalysts

ASH-C Catalysts: Innovating at the Speed of Business

As processing industries change at more rapid rates than ever before, ASH keeps up with your business needs. Meet the increasingly complex set of challenges for the refining and petrochemical industries head on with ASH’s streamlined development techniques. We develop new catalysts faster and more efficiently – catalysts that are designed to meet today’s challenges and anticipate the challenges of tomorrow. We invest in the necessary research and development to make sure that your business runs smoothly and your profits grow. Using ASH catalysts gives you the flexibility to process different feedstock’s helping you deliver whatever shifting demands dictate. You can reduce your operating expenses and pass more stringent regulations with our catalysts specifically developed for petrochemical processes. The ASH breakthrough in zeolite catalysts vastly improved process economics for many primary petrochemical building blocks. ASH continues to make advances in catalysts every day to improve your product quality and optimize your operation.

Catalyst for converting plastic wastes into middle distillate products

FeedCatalyst
Mixed Polymers ASH-C100
High Density Poly Ethylene (HDPE) ASH-C101
Low Density Poly Ethylene (LDPE) ASH-C102
Poly Propylene (PP) ASH-C103
Polyolefins (HDPE+LDPE+PP) ASH-C104
Poly Styrene (PS) ASH-C105
Poly Ethylene Terephthalate (PET) ASH-C106
Poly Vinyl Chloride (PVC) ASH-C107
Catalyst for converting heavy vacuum gas oil into light hydrocarbons
HVGO ASH-C200
Catalyst for change of API in crude oil from 10 to 30
Crude oil ASH-C300

 

Recycling material is one of the important environmental agenda defined in 3R. Instead of simply reusing the material as it is, successful chemical reusing is a more effective way reducing the use of natural resources and environmental damage incurred thereof. We would like to draw your attention to our new process and a pertinent effective plant which successfully converts plastic wastes into wax-free hydrocarbon such as naphtha and diesel oil.

 

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Special features

[1] Possible to crack mixture of plastics (PP/PE/PS) which are difficult for mechanical recycle

Small impurities such as sand, dirt and metal are processable.

[2] 100kg waste plastics can be converted into max. 100L cracked oil
(up to input materials) Yield is 86% in case of mixture of PP, PE, PS

[3] No solidification even under low temperature (WAX-FREE)

[4]  Low residual chlorine (below 100ppm), even if 10% of PVC is mixed

[5] Simple oil-converting process; continuous operation for max. 5 days

[6] Oil of good quality derived (high percentage of light oil “Naphtha, diesel, kerosene”)

[7] Low running cost (using cheap catalyst ASH-C100)

 

Comparison with ordinary waste-to-fuel method

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Property table of cracked oil using RTP

 

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Q.1 Features of this plant?
A:
Our new breakthrough oil conversion plant is quite different from the ordinary one. We call this “Continuous waste plastic catalytic cracking oil production” plant. It can operate continuously until the activity of catalyst decreases the activity can be reactivated by burning off the deposited coke. With its unique system, high performance with low production cost is achieved. Our plant size is smaller than ordinary types.

Q.2 processing capacity?
A:
Processing ability: max. 4,800kg/day (RTP-200),max. 9,600kg/day (RTP-400)
Maximum operating time: 5 days straight without catalyst exchange
Residue clean up and catalyst exchange: every 5 days
(Possible for 1-month non-stop operation at a maximumby adopting a new way of continuous catalyst exchange.)

Q3. How does it process? 
A:
(1) Crushed plastics (less than 15 mm size) are fed into the hopper on the top of the plant.
(2) Plastics are sent to the reactor through the vertical pipes controlled by several valves without melting.
(3) Plastics are rapidly heated to 400-450Ž by catalyst for gasification.
(4) Cracked gas goes to the condensers and turned into naphtha,diesel oil and heavy oil. Those are stored in separate tanks.
(5) Off gas can be used as combustion fuel for heating the reactor.

Q.4 What’s different from the popular method?
A:
There are more than 20 makers of waste-plastics-to-oil conversion plant in Japan. Most of them are non-catalyst batch system. The batch system has low thermal efficiency, because the reactor should be cooled off in every batch for safety reasons.
Unlike the batch system, our new method allows 5 days continuous operation with high yield of cracked oil.

Q.5 Safety and environmental issue?
A:
(1) Chlorine gas from PVC (Polyvinyl Chlorine) can be neutralized and eliminated by a neutralizer, thus the chlorine density in the cracked oil is controlled below 100 ppm.
(2) Off gas and its odor does not influence the atmosphere because off-gas is used as combustion fuel for heating the reactor. (3) No special considerations are required for reducing noise and vibration generated from the plant because of its structural arrangement.
(4) Cooling water doesn’t get contaminated since it is used cyclicality only, so it can be discharged directly to the sewers without any treatment.
(6) The hot air from the blower is not contaminated and can be released directly into the atmosphere.

Business benefits by adopting our product

1. Achievement of zero emission recycle initiative
2. Cost reduction in incineration/disposal landfill of waste plastics
3. New profitable business in selling of cracked oil as product

 

Vacuum Gas Oil Conversion

FCC, Unicracking, and VGO Unionfining processes are the keys to cost-effective upgrading of Vacuum Gas Oil.

These treating and conversion technologies, used alone or more typically in combination, can produce a wide range of diesel/gasoline ratios while meeting stringent product specifications. Feedstock blends of VGO and deasphalted oil, coker gas oils, and residue hydroprocessing products can also be effectively upgraded to further increase net fuel oil conversion.

Unmatched experience combined with continuous innovation

 

The ASH FCC process with using catalyst ASH-C200 can help you achieve your refining and petrochemical objectives by converting straight-run atmospheric gas oils, vacuum gas oils, certain atmospheric residues and heavy stocks recovered from other refinery operations into high-octane gasoline, light fuel oils and olefin-rich light gases like propylene for petrochemical use and butenes needed for the alkylation process.

ASH first developed FCC technology in the 1940s, but we continue to evolve this technology focusing on continuous process-design innovation. Many of today’s state-of-the-art FCC units utilize advanced technologies to enhance catalytic cracking and reduce thermal cracking for significantly higher yields of desired products.

Technology: Upstream

ASH-C300 is a novel, catalytic process that offers the disruptive ability to upgrade heavy-sour crude oil, providing an increase in value as high as 5% -30%. ASH-C300 is an innovative leap in upgrading technology that operates at much lower costs than existing upgrading processes. Because ASH-C300 has a small footprint, oil producers can field upgrade heavy-sour oil while drastically improving their economics. ASH-C300 has been proven to be effective on many heavy-sour crude oils as well as bitumen and coal liquefaction product.

Increase API gravity. Increasing API gravity can increase the value of a crude by 5% to 30%. For example, raising oil sands bitumen API from 10 to 20 eliminates the need for diluent and can provide a revenue boost of $10-$20/bbl. Other heavy crudes will see benefits closer to the 5%-10% range.

Sulfur Reduction. Sulfur levels above 1% get discounted 2%-5% depending on many factors including sulfur level. ASH-C300  can target and achieve specific sulfur levels depending on the desired quality of crude oil, increasing the overall value of the oil.

TAN Reduction. For heavy-sour feeds that have naphthenic acid levels in the 3%-4% range, producers are forced to sell their crude at a discounted rate. Removing TAN not only increases value but allows crudes to be sold to a larger portion of the refinery market, not just complex refineries that are able to process high TAN.

Metals and nitrogen reduction. Crude with high metals and nitrogen content is discounted along with other entrained contaminants. While the life of the ASH-C300 catalyst is not reduced by contact with these heteroatoms, metals and nitrogen have an adverse effect on other catalytic processes downstream. ASH-C300 treated crude oil will allow the refiners to achieve longer catalyst life and reduced process intensity, thus increasing the value of the crude oil.

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