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Innovation Challenges in
Technology Development

     Stanley A. Gembicki
     Chief Technology Officer
            uop LLC


            CDMA
        September 30, 2004
UOP LLC
 World’s largest process technology licensing
 company
  – 30,000+ patents
  – 70 licensed processes

 90 years of providing innovative solutions for
 the hydrocarbon processing industry
 General Partnership – owned 50/50 by
 business units of Dow & Honeywell
  – Independent operation - not a subsidiary of either
    company

 About 2,800 employees – 50% in technology
 invention, development & delivery
UOP LLC
                 Develop technology that provides
                 solutions to problems
                 Transfer technology to customers
                   – Refining
                   – Petrochemical
                   – Gas Processing
                   – Manufacturing Industries
                 License, design, engineer,
                 and service process technology
                 Manufacture & supply catalysts,
                 molecular sieves, adsorbents, and
                 specialized equipment


Continuing Innovation is Our Lifeblood
Today, I Would Like to Talk
         About …..
The challenges, enablers, and tools for
technology innovation in the 21st century
  – Defining the challenge, bypassing
    previously determined “limits

The role of innovation in meeting the current
challenges of the chemical industry
  – Industry outlook and key drivers
Process Industry Background

The history of the Chemical Industry is
 a story of technical accomplishment
 and innovation.
Achievements during the last century
 have led to both tremendous growth
 and a high level of technical
 sophistication.
The Need for Innovation


             The 21st Century
             poses many
             challenges
Innovations, cumulative
                          Major Innovation Has Slowed

                          60
                          50          Products
                          40
                          30                   Processes
                          20
                          10
                           0
                           1930 1935 1940 1945 1950 1955 1960 1965 1970 1975 1980 1985 1990
                                                         Year
                   Product and process innovations from 1930 to 1985 are shown
                  Source: Chemtech 1995, 25(6), 6.
“I think the Greeks are running out of ideas!”

     © The New Yorker Collection 1991 James Stevenson from cartoonbank.com. All Rights Reserved.
                                                              cartoonbank.com.
     [for: 1991 07 15 060 JST .HG I think] sent as Greeks.JPG
Continuous Innovation and Improvement:
       Fluid Catalytic Cracking
                                                                   Theoretical Octane Barrels
                                      6,200
                                                                                                 New Reactor
  Octane Barrels / 100 Barrels Feed




                                                                                                  Concepts
                                      6,000
                                                                                 Improved Reaction
                                                                                     Systems
                                      5,800
                                                                     Octane Catalysts
                                      5,600
                                                           Extended Riser
                                      5,400
                                                     Zeolite Catalysts
                                      5,200
                                              Amorphous
                                               Catalysts
                                      5,000
                                                              Octane Barrel Capacity of FCC
                                      4,800
                                              1950        1960           1970      1980         1990      1996
The Technology Innovation Cycle
    Industry Need
    and/or Value                         Pilot Plant     Sell Concept
                           Research     Development      to Producer
     Proposition




                          Commercial   Troubleshooting   1st Demo or
                                        Optimization     Commercial
                            Success                          Plant

 Operating Experience
 Incremental Process                    Long history of continuous
    Improvements
   New Equipment
                                        innovation in the Chemical
New Catalytic materials                          Industry
Steps for Increasing
      the Rate of Innovation
Have the mindset that innovation is not just
about technology
Work on the right problems
Increase the focus on radical versus
incremental innovation
Leverage internal capabilities with external
capabilities
Speed is essential, have a sense of urgency
Chemical Industry Realities
Clean Fuels
- Cost Effective Ways to produce zero
  sulfur/low nitrogen transportation fuels
Non Conventional Feedstocks
 - Stranded Natural Gas
- Renewable sources
Improved Industry Profitability
- Invest capital required for expected
   capacity requirements
- Lower capital intensity
- Reduce variable costs
Minimize Environmental Impact
- Plant emissions
- Spent catalyst handling
Innovation Enablers
Combinatorial Chemistry Approach to Discovery
Advanced Catalyst Characterization at the
 Atomic Level
The Application of Theoretical Methods
to Catalysis to Understand Active Site
Structure and Mechanism
The Discovery of New Materials,
Zeolites, NZMS, and their
Application to Catalysis
Process Miniaturization and
Intensification
Increasing Barrier to Technology
  Innovation: Commercialization


             Pilot Plant   Sell Concept    Commercial
Research                   to Producer    Demonstration
            Development




      With new tools to drive innovation,
   the focus shifts to challenges downstream
     in new technology commercialization
Less Desire to Take Risk
Industry Consolidation
  – Fewer, bigger companies
Profitability Challenges
Larger plant sizes for
economy of scale
Limited discretionary
capital spending in
refining                 Let someone else be
                          the first to try new
                             technology!
Summary
The Chemical Industry faces a number of
significant challenges: feedstock availability;
sustainability realities; profitability; capital
intensity
While technology is maturing in many markets,
new “enablers” exist to push technology
developments into the new century. Meeting key
industry needs
Industry trends are increasing the reluctance of
producers to take risks in being the first to
commercialize new technology
“Partnering” between Technology developers and
“Users” is critical to overcoming these barriers

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Gembicki presentation

  • 1. Innovation Challenges in Technology Development Stanley A. Gembicki Chief Technology Officer uop LLC CDMA September 30, 2004
  • 2. UOP LLC World’s largest process technology licensing company – 30,000+ patents – 70 licensed processes 90 years of providing innovative solutions for the hydrocarbon processing industry General Partnership – owned 50/50 by business units of Dow & Honeywell – Independent operation - not a subsidiary of either company About 2,800 employees – 50% in technology invention, development & delivery
  • 3. UOP LLC Develop technology that provides solutions to problems Transfer technology to customers – Refining – Petrochemical – Gas Processing – Manufacturing Industries License, design, engineer, and service process technology Manufacture & supply catalysts, molecular sieves, adsorbents, and specialized equipment Continuing Innovation is Our Lifeblood
  • 4. Today, I Would Like to Talk About ….. The challenges, enablers, and tools for technology innovation in the 21st century – Defining the challenge, bypassing previously determined “limits The role of innovation in meeting the current challenges of the chemical industry – Industry outlook and key drivers
  • 5. Process Industry Background The history of the Chemical Industry is a story of technical accomplishment and innovation. Achievements during the last century have led to both tremendous growth and a high level of technical sophistication.
  • 6. The Need for Innovation The 21st Century poses many challenges
  • 7. Innovations, cumulative Major Innovation Has Slowed 60 50 Products 40 30 Processes 20 10 0 1930 1935 1940 1945 1950 1955 1960 1965 1970 1975 1980 1985 1990 Year Product and process innovations from 1930 to 1985 are shown Source: Chemtech 1995, 25(6), 6.
  • 8. “I think the Greeks are running out of ideas!” © The New Yorker Collection 1991 James Stevenson from cartoonbank.com. All Rights Reserved. cartoonbank.com. [for: 1991 07 15 060 JST .HG I think] sent as Greeks.JPG
  • 9. Continuous Innovation and Improvement: Fluid Catalytic Cracking Theoretical Octane Barrels 6,200 New Reactor Octane Barrels / 100 Barrels Feed Concepts 6,000 Improved Reaction Systems 5,800 Octane Catalysts 5,600 Extended Riser 5,400 Zeolite Catalysts 5,200 Amorphous Catalysts 5,000 Octane Barrel Capacity of FCC 4,800 1950 1960 1970 1980 1990 1996
  • 10. The Technology Innovation Cycle Industry Need and/or Value Pilot Plant Sell Concept Research Development to Producer Proposition Commercial Troubleshooting 1st Demo or Optimization Commercial Success Plant Operating Experience Incremental Process Long history of continuous Improvements New Equipment innovation in the Chemical New Catalytic materials Industry
  • 11. Steps for Increasing the Rate of Innovation Have the mindset that innovation is not just about technology Work on the right problems Increase the focus on radical versus incremental innovation Leverage internal capabilities with external capabilities Speed is essential, have a sense of urgency
  • 12. Chemical Industry Realities Clean Fuels - Cost Effective Ways to produce zero sulfur/low nitrogen transportation fuels Non Conventional Feedstocks - Stranded Natural Gas - Renewable sources Improved Industry Profitability - Invest capital required for expected capacity requirements - Lower capital intensity - Reduce variable costs Minimize Environmental Impact - Plant emissions - Spent catalyst handling
  • 13. Innovation Enablers Combinatorial Chemistry Approach to Discovery Advanced Catalyst Characterization at the Atomic Level The Application of Theoretical Methods to Catalysis to Understand Active Site Structure and Mechanism The Discovery of New Materials, Zeolites, NZMS, and their Application to Catalysis Process Miniaturization and Intensification
  • 14. Increasing Barrier to Technology Innovation: Commercialization Pilot Plant Sell Concept Commercial Research to Producer Demonstration Development With new tools to drive innovation, the focus shifts to challenges downstream in new technology commercialization
  • 15. Less Desire to Take Risk Industry Consolidation – Fewer, bigger companies Profitability Challenges Larger plant sizes for economy of scale Limited discretionary capital spending in refining Let someone else be the first to try new technology!
  • 16. Summary The Chemical Industry faces a number of significant challenges: feedstock availability; sustainability realities; profitability; capital intensity While technology is maturing in many markets, new “enablers” exist to push technology developments into the new century. Meeting key industry needs Industry trends are increasing the reluctance of producers to take risks in being the first to commercialize new technology “Partnering” between Technology developers and “Users” is critical to overcoming these barriers