STAR process technology Robust on-purpose propylene production technology

Transcription

1 STAR process technology Robust on-purpose propylene production technology January 2017 The Ritz Carlton, Manama, Bahrain thyssenkrupp Industrial Solutions Martin Cosfeld

2 Introduction Who are we?

3 thyssenkrupp Business Areas Key indicators fiscal year 2014/ Components Technology Elevator Technology Industrial Solutions Materials Services Steel Americas Steel Europe Sales [mn ] 6,753 7,208 6,256 14,254 1,773 8,697 EBIT² [mn ] (138) 492 Employees 29,627 51,335 19,388 20,226 3,725 27,601 thyssenkrupp AG Sales: 42,778 mn EBIT adj.²: 1,676 mn Employees: 154, Continuing operations (after reclassification of Steel Americas) 2. Adjusted before consolidation January 2017 MERTC, The Ritz Carlton, Manama, Bahrain STAR process - Robust on-purpose propylene production technology Martin Cosfeld

4 thyssenkrupp Industrial Solutions Process Technologies Outstanding technology portfolio with full process chain offerings Feedstocks Natural gas/ Shale gas Crude oil Coal Salt Renewable resources Steam reforming Autothermal reforming Steamcracker Propane dehydrogen. Oil refinery Coking plant Gasification/ power plant Chlor-alkali electrolysis Refining/ fermentation Ammonia Hydrogen Methanol to Gasoline Methanol Ethylene oxide Ethylene Propylene Benzene Toluene Xylene Gasoline, diesel Lube oil, waxes Coke Fischer-Tropsch synthesis Chlorine Caustic soda sol. Sugar Intermediates Urea Ammonium nitrate Nitric acid Formaldehyde Ethylene glycol Propylene oxide Caprolactam Terephthalic acid Ethylene dichloride Bioethanol Succinic acid Lactic acid Granulation Granulation EnviNOx Urea/Formaldehyde Polyethylene Polypropylene Polyurethane Polyamide Polyester Hydrogen Vinyl chloride Polylactic acid PVC Fertilizers Adhesives, synthetic resins Plastics Fuels End products Lubricants, waxes Steel Electric power Fuels Fine chemicals Bioplastics Uhde technology Core licences important intermediate stage January 2017 MERTC, The Ritz Carlton, Manama, Bahrain STAR process - Robust on-purpose propylene production technology Martin Cosfeld

5 STAR process Light olefins production via dehydrogenation of propane and butanes

6 STAR process Market view: On-purpose production of propylene growing Demand Mainly driven by growing demand for Polypropylene (PP) Other products are Propylene Oxide, Cumene, Acrylonitrile, Acrylic Acid, Oxo Alcohols Supply Demand for propylene outpaces supply from conventional sources (Steam Cracking, Fluid Catalytic Cracking) Refinery economics & improved fuel efficiency affecting supply from refineries Conclusion On-purpose production of propylene required Share of on-purpose technologies growing from 7% in 2000 to >30% in 2022 Source: IHS, January 2017 MERTC, The Ritz Carlton, Manama, Bahrain STAR process - Robust on-purpose propylene production technology Martin Cosfeld

7 STAR process Brief history & references since 1960s: Development by Phillips Petroleum 1992: Commissioning of first commercial STAR plant, Coastal Chem, Wy, USA 1994: Commissioning of second commercial STAR plant, PBA, Ensenada, Argentina 1999: Technology and catalyst acquired by TK Uhde incl. all patents, rights : Enhancement of technology 2007: LSTK contract: first commercial PDH plant based on STAR process 2009/11/13: 3 contracts: License & basic engineering incl. supply of proprietary equipment and catalyst plus technical assistance services Coastal Chemicals Wyoming, USA Commissioning in ,000 t/a Isobutylene MEPEC Iran Commissioning in 2018/19 425,000 t/a Propylene Formosa Plastics Corporation Texas, USA Commissioning in 2018/19 545,000 t/a Propylene EPPC Egypt Commissioning in ,000 t/a Propylene SFPC Iran Commissioning in 2018/19 425,000 t/a Propylene Polybutenos Argentina Commissioning in ,000 t/a Isobutylene January 2017 MERTC, The Ritz Carlton, Manama, Bahrain STAR process - Robust on-purpose propylene production technology Martin Cosfeld

8 STAR process Reaction chemistry (Dehydrogenation) Main reaction C 3 H 8 C 3 H 6 + H 2 C 4 H 10 C 4 H 8 + H 2 (+ 124 kj/mol) By-products CH 4, C 2 H 4, C 2 H 6, CO 2 Coke formation Cracking of hydrocarbons (HC) Coke conversion C + H 2 O CO + H 2 C + 2 H 2 O CO H January 2017 MERTC, The Ritz Carlton, Manama, Bahrain STAR process - Robust on-purpose propylene production technology Martin Cosfeld

9 STAR process Block Flow Diagram (typical) January 2017 MERTC, The Ritz Carlton, Manama, Bahrain STAR process - Robust on-purpose propylene production technology Martin Cosfeld

10 STAR process Uhde Reformer References Fixed bed reactor More than 70 steam reformers since 1966 Simple, reliable and robust in operation Commercial reformers operate over a wide range: 40 bar C bar C bar 880 C 9-12 bar 900 C Olefins 5-6 bar C EPP Port Said January 2017 MERTC, The Ritz Carlton, Manama, Bahrain STAR process - Robust on-purpose propylene production technology Martin Cosfeld

11 STAR process STAR catalyst o Commercialised o Platinum promoted basic calcium and zinc aluminate o Stable in presence of steam and oxygen at high temperature o High selectivity at near equilibrium conversion o Regeneration is simple and sustainable o No chemicals for catalyst activation or coke suppression Reduced OPEX; no environmental issues o TKIS supplies certified catalyst o Same catalyst for PDH and BDH o Continuous catalyst development program on-going January 2017 MERTC, The Ritz Carlton, Manama, Bahrain STAR process - Robust on-purpose propylene production technology Martin Cosfeld

12 STAR process Are your real costs under the surface? OPEX CAPEX Operability OPEX CAPEX Operability Feedstock Energy Cooling water Catalyst Chemicals / adsorbents Process License + PDP Engineering Procurement Construction Other costs (land, etc.) Safety / environment Loss of production Reputation Quality Delivery issues January 2017 MERTC, The Ritz Carlton, Manama, Bahrain STAR process - Robust on-purpose propylene production technology Martin Cosfeld

13 STAR process CAPEX advantages: Lowest investment on the market Highly efficient reaction section Lowest catalyst inventory / reactor volume on the market Simple in-situ regeneration High reaction operation pressure / low operation temperature Lowest compression costs on the market Less MA/PD and C 5 + byproducts Low regeneration air demand Standardized air compressor design can be applied E-motor or steam turbine drive may be used January 2017 MERTC, The Ritz Carlton, Manama, Bahrain STAR process - Robust on-purpose propylene production technology Martin Cosfeld

14 STAR process CAPEX advantages: Do not only look on single-pass conversion - an example for the three most expensive units Reactor / catalyst volume Cheapest reactor system on the market Only process with direct heating of the reaction zone Raw gas compressor Smallest compressor on the market High suction pressure leads to low compression ratio and low inlet volume flow C3 Splitter Reactor conversion almost irrelevant for C3 splitter dimensions Position of feed tray depends on propylene concentration Reflux ratio / reboiler duty dominated by propylene product purity January 2017 MERTC, The Ritz Carlton, Manama, Bahrain STAR process - Robust on-purpose propylene production technology Martin Cosfeld

15 STAR process Operability advantages Fixed bed reactor type No moving catalyst or hot switching valves Simple and robust operation less maintenance High availability and reliability Independent parallel reactor trains Olefins production without Cold Box possible Shortest start-up and overall shut-down time Shorter re-start from hot stand-by Demonstrated plant availability of >98% January 2017 MERTC, The Ritz Carlton, Manama, Bahrain STAR process - Robust on-purpose propylene production technology Martin Cosfeld

16 Profit [% of base case] STAR process Case study: Feedstock and avalability dominate plant profitability Production (Availability) Utility costs Investment Costs % -5% 0% Change of parameter 5% 10% Feedstock costs Base Case UOM Value Capacity kta 450 Depreciation %/a 5 Operating Hours h/a 8000 Propane (100% basis) USD/ton 500 Propylene USD/ton January 2017 MERTC, The Ritz Carlton, Manama, Bahrain STAR process - Robust on-purpose propylene production technology Martin Cosfeld

17 Integration Options Highly efficient plant concepts due to integration of PDH with downstream technologies and utilities Utilities PO / PP PDH

18 Integration Options HPPO process H 2 O 2 License jointly by Evonik & thyssenkrupp Catalyst by Evonik HPPO Engineering by thyssenkrupp PO producer Advantages of technology Co-product-free process Combination of efficient heat transfer with an almost ideal plugflow characteristic through specially designed epoxidation reactor High-performance catalyst with a long lifetime Chlorine-free process Optional use of polymer-grade or chemical-grade propene feedstock Economic benefits Lower capital investment and energy consumption compared to state-of-the-art PO technologies High specific yields resulting in low feedstock consumption Stand-alone technology: no market dependency on co-products Less costs, less space, less energy & no co-products January 2017 MERTC, The Ritz Carlton, Manama, Bahrain STAR process - Robust on-purpose propylene production technology Martin Cosfeld

19 Integration Options Polymer Experience ID257 Product Projects Technologies HDPE slurry 35 1 LDPE 22 5 LL/MD/HDPE 5 4 First Polymer Plant built in 1959 More than 90 polyolefin plants world-wide - high pressure processes - suspension processes - fluidised gas phase processes - stirred gas phase processes - multizone processes PP 30 4 PVC (S+E) 37 3 Contracts for polyolefin plants covering capacities of over 10 million mt/y have been awarded to TKIS up to now. Focus on technology (Study, PDP and FEED preparation), EPC competencies, experience in revamps and plant optimizations January 2017 MERTC, The Ritz Carlton, Manama, Bahrain STAR process - Robust on-purpose propylene production technology Martin Cosfeld

20 Integration Options Contribution to a successful petrochemical investment ID257 o Licensor for PDH & PO Technology o Engineering and operation know how in PDH, PO and PP o Fast track project delivery (PDP and FEED in parallel for PDH, PO and PP) o Conceptual engineering for PDH, PO, PP, offsites and utilities o Single point of contact (engineering for all plants and facilities out of one hand; PP license can be aquired via TKIS) o EPC capabilities with local setup and global sourcing January 2017 MERTC, The Ritz Carlton, Manama, Bahrain STAR process - Robust on-purpose propylene production technology Martin Cosfeld

21 Integration Options Reference EPP PDH Plant EPP PDH/PP site view Location: Port Said, Egypt Description of the complex: PDH Plant: 350,000 MTA Propylene (TKIS STAR process ) PP-Plant: 350,000 MTA Polypropylene (Basell Spheripol Process) Offsites & Utilities Plant: Steam Generation, Cooling Tower, Refrigeration Unit, Air Separation Unit, H 2 Generation, Storage, Flare, etc. Feed: Propane, Natural Gas, Raw water, Electricity Target Products: Bulk Stable Fibre (carpets); Film; Raffia Project Scope: EPC LSTK including license for PP and PDH Savings due to integration: approx. 5% of TIC January 2017 MERTC, The Ritz Carlton, Manama, Bahrain STAR process - Robust on-purpose propylene production technology Martin Cosfeld

22 Summary

23 Summary Reliable, safe and low investment costs o Operation in presence of steam reduced coking prolonged reaction cycles o Reactor system: Highly efficient, commercially proven top fired reformer o High availability / reliability: a) Fixed bed reactor principle b) Simple in-situ regeneration c) Production without cold box possible d) Independent parallel reactor trains e) Short start-up and overall shut-down time o o Integration with PP or PO plants leads to more viable projects Execution out of one hand (PDP + EPC) leads to shorter project time single point of responsibility January 2017 MERTC, The Ritz Carlton, Manama, Bahrain STAR process - Robust on-purpose propylene production technology Martin Cosfeld

24 Poll question Were is the major market for on-purpose propylene production? a)mena b)usa c)canada d)asia (esp. China) January 2017 MERTC, The Ritz Carlton, Manama, Bahrain STAR process - Robust on-purpose propylene production technology Martin Cosfeld

25 Thank you! January 2017 MERTC, The Ritz Carlton, Manama, Bahrain STAR process - Robust on-purpose propylene production technology Martin Cosfeld