Tüpraş and EU Project: MACBETH

Tüpraş and EU Project: MACBETH (Membranes and Catalysts Beyond Economic and Technological Barriers) In process industries, refinery processes are among those consuming the most energy and resources. To help Europe achieve its goal of a clean and liveable environment, innovative processes with broad applicability need to be effectively integrated into the refinery process chain. This will significantly enhance the competitiveness of Europe's process industry by reducing operational costs. The MACBETH consortium presents a breakthrough technological advancement by combining catalytic synthesis and accompanying separation units integration into a single, custom-built, efficient catalytic membrane reactor (CMR). [caption id="attachment_158060" align="aligncenter"] Tüpraş R&D Project Team[/caption] Twenty-seven partners with diverse expertise and capabilities in catalytic processes and membrane technologies have come together in the MACBETH project for the first time to transfer the developed technology to other sectors of the chemical industry. The MACBETH consortium combines the catalytic synthesis step with a highly efficient separation step achieved through a specially designed membrane. Previous EU-funded projects—ROMEO, BIONICO and CARENA—and other foundational developments have established a strong basis by demonstrating the following processes for CMR (catalytic membrane reactor) at technology readiness level 5 (TRL-5): i) Hydroformylation (HYFO), ii) Hydrogen production (H2), iii) Propane dehydrogenation (PDH). Members of this consortium are working together in the MACBETH project to advance CMR technology to TRL 6/7 level and to establish the foundation for progress toward commercialisation of three new technologies. Furthermore, the knowledge and experience gained from the three aforementioned successful European Union projects form the basis for custom-designed CMR solutions applicable on a broad scale across nearly every sector of the process industry requiring separation after catalytic synthesis. Additionally, to demonstrate applicability levels, MACBETH extends CMR technology to the biotechnology field, where bacteria or enzymes are used as special catalyst forms in biotechnological reactions. In this area, selective enzymatic cleavage of fatty acids is of particular commercial interest. For the first time, commercial applicability of CMR technology in biotechnology will be demonstrated using a demo facility for bio-catalytic fat decomposition (BOC). The conversion of olefins and synthesis gas into aldehydes, known as hydroformylation and used in the chemical industry for the production of specialty chemicals, is an important reaction. Hydroformylation (HYFO) reaction technology focuses on optimising: i) The type and structure of catalyst support material for efficient utilisation of the catalytic system, ii) The catalytic system enhancing yield and selectivity, iii) The polymeric membrane for separation efficiency and permeate flux, iv) Operating conditions. The HYFO demo operation will be conducted at the conventional hydroformylation production facility at Evonik's Marl site under industrial-scale conditions. In the H2 technology used in MACBETH, natural gas or biogas is reformed with methane in a single reactor, and H2 can be produced at a much lower temperature through CMR integration, which provides H2 separation. This increases overall process efficiency from 59% to over 70% for biogas and improves cost efficiency by reducing the number and volume of units in the process. Another work area of the project, propylene production from propane, is an important process for various chemical sectors. Propylene is used in the production of widely used chemicals such as polypropylene, acrolein, acetone and polyacrylonitrile. Propylene is conventionally obtained as a by-product of ethylene production and as a result of cracking petroleum-derived naphtha. To meet rising propylene demand with adequate supply, an alternative production process is needed. Catalytic propane dehydrogenation (PDH) is a cost-effective alternative to catalytic cracking reactions for closing the gap between increasing global demand and existing production capacity. The innovative catalyst developed in the MACHBETH project achieves high propylene selectivity and high propane conversion whilst reducing catalyst deactivation. Operating conditions created using the innovative catalyst require less catalyst regeneration, thereby providing longer catalyst life. Additionally, improved propylene selectivity significantly reduces by-products and increases plant profitability. Türkiye Petrol Rafinerileri A.Ş. (Tüpraş), through its four refineries (İzmit, İzmir, Kırıkkale, Batman), has been supplying Turkey's energy as the country's leading oil company for over 60 years. Tüpraş has committed to reducing greenhouse gas emissions and achieving carbon neutrality by 2050. In line with this goal, Tüpraş has shaped its strategy and investment within the scope of sustainable refining, biofuels and green H2. Tüpraş, in line with its strategic goals, participates in many innovative EU projects such as MACBETH, which aim to develop processes to reduce greenhouse gas emissions. Tüpraş is tasked with PDH technology in the MACBETH project and has two main roles. The first role, defined during the project proposal phase, is to scale up at the laboratory level the best-performing Pt-based PDH catalyst examined and identified by another project partner, University of Salerno (UNISA), for use in Tüpraş PDH demo facility. The second role is to test the developed membrane and catalyst in the MACBETH project and demonstrate PDH technology at TRL 6 level. Tüpraş has produced different catalysts using the Pt-based reference catalyst identified by UNISA. The PDH catalysts developed and produced by Tüpraş, taking into account the final catalyst compositions determined by UNISA, are being tested at Tüpraş facilities. After various reaction tests, Tüpraş achieved the project target of 95% propylene selectivity, and the long-term tests of the catalyst were completed successfully. Tüpraş will produce approximately 1 kg of the best-performing catalyst for use in the demo operation. Additionally, Tüpraş will integrate CMR technology into the PDH pilot facility and complete demo-scale trials through 500 hours of continuous operation in the first quarter of 2024. [caption id="attachment_158061" align="aligncenter"] Tüpraş PDH pilot facility before revamp[/caption] [caption id="attachment_158062" align="aligncenter"] PDH catalyst produced by Tüpraş[/caption]