© 2003, Exxon Mobil Corporation All Rights Reserved

““Perspective on Refining and Perspective on Refining and

Petrochemicals Petrochemicals

Catalysis at Catalysis at NanoscaleNanoscale““

S. Mark DavisS. Mark Davis

NSF Catalysis WorkshopNSF Catalysis Workshop

June 19-20, 2003June 19-20, 2003

950 Million

Gallons Per Day (World Wide)

3.2 Billion 1.8 Billion

CrudeProduction

Refining &Chemicals Fuel

Gasoline

Diesel

850 MillionToday’s Infrastructure• Massive• Global• Highly Efficient• 100 Years in Making

Large and Complex Industry

300 Million

Chemicals

Trends in Refining Catalysis

Trends: Improved selectivityEnergy efficiencyBetter utilization of hydrocarbonsUtilization of unconventional feedstocksCombined reaction and separationIntermaterial substitution

“Refinery of the Future” or “Energy Plants”– Distributed Power Production– Flexible Feedstock– Flexible Product Production

Energy Efficiency Focus

ProductRegulationFocus

Short-term

Medium-term

Longer-term

Tailored Structure andStructure Property Control atNanoscale Important for Next

Generation Catalysts

High Throughput Methods ChangingR&D Work Process

Analysis

Experimental Design

Automation &Robotics

High SpeedAnalysis

DatabaseManagement

Informatics

Robotics

Analytics 12

34

56

AB

CD

EF G I0.E+00

4.E+05

8.E+05

1.E+06

2.E+06

Mw

Activator Catalyst

60Å

100Å

20Å

40Å

Zeolite YZSM-5

Pore Size A

406080100

5

10

20

MCM-41

Gasoil ResidsGasolineChemicals

°

Shape Selective Catalysis Key toManaging Molecular Size & Shape

• MCM-41 Commercial Catalytic Nanotechnology Example

• Exciting New EM Materials Now Entering Pipeline

© 2003, Exxon Mobil Corporation All Rights Reserved

Surfactant Micelle

Micelle RodHexagonal Array

Calcination

MCM-41

Silicate

MCM-41: What Is It?

Clad the Surface

Vary ChemicalComposition

Vary Pore Size1.5nm to >10nm

Anchor Metalsand Catalysts

Many Options for Tailoring Microstructure

and Reactivity

SCANfining™ Leading CatNaphtha (Gasoline)Desulfurization Process- Removes sulfur, No Vol. Loss- Minimizes Octane Loss

- 28 Units Planned/Operating

Nebula™ Superior Catalystfor Diesel Processing– Most Active Catalyst Known– Lowers Investment to Meet

Low-Sulfur Diesel

SCANfining™ Catalyst RT-225

Maximize HDS

S+H2 +H2S

+H2

Minimize Olefin Saturation

Achieving Lower FuelSulfur Levels

© 2003, Exxon Mobil Corporation All Rights Reserved

0 KF-843 DN-190 KF-848 "Nebula"™

Relative Volume Activity, %

0

Site Property Control in Powders and Pellets Via Synthesis Strategies

....

....

Non Classical Synthesis:- Produce new or metastable catalyst precursors [hydrotreating]- Structure directing methods, epitaxy control

Modifying Site Functionality: - Acid site strength and density, promoters, multifunction systems

Morphology and Distribution: - Site placement in specific environments--pellets or powders - Metals, compounds, promoters

Lessons Learned

• The Hard Part Isn’t Discovery…It’s Development and Commercialization

• Partnerships, High Throughput Methods, and Modeling AreDecreasing Cycle Times to Commercialize Breakthrough R&D

- Oil-Auto Examples Aftertreatment and On-Board Reforming

• Coupling Nanotechnology Developers with ApplicationsDevelopers is Essential

- Academic Spin-Off Companies- Established Technology Suppliers- National Laboratories- Iterate/Optimize with Technology Users

• Evolving Industrial Research LandscapeWill Likely Lead to More Multi-Party Cooperation

Hybricats: Vision for theFuture

Today’s Capabilities

Shape SelectiveZeolites

High ActivityMetal Oxide

Nano-structures

CombineBest

Features

•Higher Activity/Selectivity•Poison Tolerant/Longer Life•Improved Regenerability•Combined Reaction/Separation

Tomorrow’s CatalystsTailored MultifunctionZeolite--Metal Oxide Hybrids

© 2003, Exxon Mobil Corporation All Rights Reserved