Recent Technology Developments to Support Petrochemicals Demand. Laurent Samy

Transcription

1 Recent Technology Developments to Support Petrochemicals Demand Laurent Samy 1

2 Be Close to Your Needs, Our Approach Complete portfolio: processes & catalysts Strong scientific background Design efficiency Your Plant / Project Advanced services APC Simulator Close to your needs Follow-up Tech Services Start-up assistance Operators training 2

3 Providing Technologies for Petrochemicals South & Latin America Basically all countries Argentina Brazil Chili Mexico Uruguay Venezuela and all technologies AlphaButol co-monomer grade 1-butene alpha olefin Selective hydrogenations (C3, C4, pygas) Etherifications Octenes via Dimersol-X dimerization Benzene saturation Prime-G+ Reforming Isomerization 3

4 Agenda Recent Developments in Line with Market Evolution Alpha Olefins Renewables Optimization of Existing Technologies Energy Efficiency and Water Footprint Reduction 4

5 Agenda Recent Developments in Line with Market Evolution Alpha Olefins Renewables Optimization of Existing Technologies Energy Efficiency and Water Footprint Reduction 5

6 The Ethylene Plant Example Large Portfolio downstream Steam Cracking Steam Cracker Furnaces & Distillation Section MAPD selective hydrogenation Purification Multibed Ethylene Propylene Butadiene C 3 /C 4 total hydrogenation C 4 acetylenes selective hydrogenation Butadiene BD rich selective hydrogenation Butadiene Extraction C 4 etherification Catacol Dimerization AlphaButol BD lean selective hydro 1-butene maximization BD lean selective hydro 2-butene maximization Super fractionation Isobutene Purif Isopure Trimerization AlphaHexol 2-butenes rich cut Hydration Dimerization Dimersol-X Dehydrogenation 1-hexene 1-butene Isobutane Isobutene Octenes N-butane MEK MTBE, ETBE C 4 /C 5 olefins hydrogenation Skeletal isomerization Iso-5 C5 etherification Catacol Oligomerization Selectopol Polynaphtha PolyFuel Olefins hydrogenation Benzene saturation Cyclohexane Solvents TAME, TAEE Cyclohexane Removal of arsenic & mercury RAM II C 5 Pygas 1st Stage Hydrogenation (GHU-1) Pygas 2nd Stage C 6+ Hydrogenation (GHU-2) C 6 -C 8 Advanced Pygas Upgrading APU Aromatics recovery Sulfolane Morphylane Benzene Toluene Mixed xylenes Condensates C 9+ Benzene production (HydroDeAlkylation) to car fuels pool 6

7 Olefins: On-Purpose Processes Powerful tool to produce co-monomers High quality On-demand Efficient use of raw material Cost effective route Good match especially with ethane based crackers Low cost ethylene, lack of C4 s Recent south and latin Amrica context Last 3 ethylene plants s/u are ethane based Brazil: Braskem UNIB-4, Duque de Caxias Venezuela: Polinter, El Tablazo Mexico: Braskem-Idesa Etileno XXI, Coatzacoalcos 7

8 Olefins: On-Purpose Processes Success of Selectivity On-purpose Mechanism Selective formation of the alpha-olefin Not a chain growth mechanism Highly selective towards desired oligomer Carbon number Carbon number 8

9 Polymerization Alpha Olefins Production AlphaButol Selective ethylene dimerization Successful Commercialization >30 references AlphaHexol Selective ethylene trimerization Recently Born Process similar to AlphaButol, strongly backed up by extensive industrial experience in homogeneous catalysis 1 commercial reference Applications: Co-monomers HDPE & LLDPE 9

10 Adaptation through Technology Answer Ethane Based Crackers Specific Context High purity co-monomers Highly efficient ethylene use CAPEX effective solution Stereospecific chemistry made licenced technology matching market demand AlphaButol AlphaHexol TM 10

11 Agenda Recent Developments in Line with Market Evolution Alpha Olefins Renewables Optimization of Existing Technologies Energy Efficiency and Water Footprint Reduction 11

12 Preparing Tomorrow s Petrochemicals Tomorrow s feedstocks? Oil and gas: for sure, as long as available Other sources: likely to grow Renewable oils and fats Lignocellulosic biomass Growing contribution of alternatives sources Uncertain timing Preparation/development on its way Renewable Oils & Fats Oil Lignocellulosic Biomass 12

13 Biosourced Materials Providing Environmental Performance Vegan Renewable Jet & Diesel (HVO/HEFA) GREEN FUELS Gasel /BioTfueL Project High Quality JET & DIESEL Futurol Project 2G ETHANOL Atol BIO-ETHYLENE GREEN POLYMERS BioTCat Project BIO-AROMATICS BioButterfly Project BIO-BUTADIENE 13

14 Alternatives & Renewables Fuels From Biomass, Coal or Gas Gasel Fischer-Tropsch + Hydrocracking technology suite Gas Bubbles Dense phase or slurry Offgas Liquid recirculation Slurry Outlet Wax High Quality 2 nd generation Bio-Naphtha & Bio-Diesel & Bio-Jet 1 st Commercial reference: Pilot Plant Syngas inlet Slurry Return Ajos Finland From Biomass Futurol Project Cellulosic Ethanol Production Technology And others Vegan Hydroprocessing of Oils & Fats Simple and integrated 4-step process 1) Pretreatment 2) Biocatalysts production 3) Hydrolysis & Fermentation 4) Product recovery H 2 PROPANE NAPHTHA OILS & FATS HYDROTREATMENT HYDROCRACKING & ISOMERIZATION High Quality transportation Bio-Diesel & Bio-Jet Fuels 1 st Commercial reference: JET & DIESEL 14

15 Alternatives & Renewables Bio-based Petrochemicals Bio-ethylene from ethanol: Technology: Atol BIOMASS BIOMASS TO ETHANOL ETHANOL TO ETHYLENE ETHYLENE From Biomass Bio-butadiene from biomass: BioButterfly Project Technology under development: BIOMASS BIOMASS TO ALCOHOLS CATALYTIC REACTIONS & SEPARATION BUTADIENE Aromatics from biomass Bio-TCat TM Project Technology under development: NON-FOOD BIOMASS CATALYTIC FAST PYROLYSIS HYDROTREATMENT BENZENE TOLUENE PARAXYLENE 15

16 Renewable Fuels & Chemicals Futurol Technology Simplicity and Robustness compact scheme & few production steps : - Single-train pretreatment, - One-pot hydrolysis fermentation Integration and Cost Competitiveness in line with 1G bio-ethanol production costs - Energy and water management, - On-site biocatalysts production and propagation Biomass Flexibility developed and tested on a wide range of biomasses - Suitable for worldwide deployment - Possibility to take advantage of any feedstock opportunities. 16

17 Vegan Product: Premium Quality Biofuel Advantages of Renewable Diesel (HVO) Renewable Oils & Fats High blending value, oxygen-free product Transesterification CH 3 OH Biodiesel (FAME 1 ) 1 : Fatty Acid Methyl Ester 2: Hydrotreated Vegetable Oil Hydrotreatment H 2 Renewable diesel (HVO 2 ) Higher energy density Tunable cold flow properties Production of Biojet blend stock Improved ignition (higher cetane number) Better blended product stability Reduced waste & by-products production Higher feedstock flexibility (UCO, FFA, ) 17

18 Vegan Renewable Iso-paraffins Route Pretreated Renewable Oils & Fats High Quality Renewable Diesel & Jet 1 HDT 2 HDI Hydrogenation & Decarboxylation Oxygen removal, olefin saturation Hydro-isomerization (HDI) to improve cold flow properties Hydrocracking if jet is desired 18

19 Vegan Products High Blending Value Biofuels Cold Flow Properties Cetane Index Diesel Specification Diesel/Jet and Naphtha Yield Specific Gravity 100% 80% 60% 40% 20% 0%

20 Vegan Insutrial Reference Total La Mède Biorefinery Project Announced by TOTAL - April 2015 First Vegan Industrial Reference Retrofit of two HDT Units into a Vegan Unit 200 Million Euros Overall Investment Production of 500,000 t/y of Renewable Diesel Fast-track project: Start-up in 2017 (basic design already completed) 20

21 Vegan 1 st Step used for Petrochemicals Change Renewable Oils & Fats into Valuable Cracker Feed Hydrotreating of renewable oils Long chain paraffinic materials Saturated, deoxygenated Quality feedstock for steam cracking furnaces Expected yields comparison Use Vegan Technology 21

22 Major Actor for Petrochemical Intermediates > 600 selective hydrogenation references >60 etherefication units 32 co-monomer grade alpha olefins references Major Actor Refinery / Petrochemicals synergies Aromatics complexes > 20 ParamaX > 25 Eluxyl FCC alliance Axens Technip IFPEn Total > 60 units Others Octenes via Dimersol-X C4 purifications Vegan 22

23 Agenda Recent Developments in Line with Market Evolution Alpha Olefins Renewables Optimization of Existing Technologies Energy Efficiency and Water Footprint Reduction 23

24 Basic Engineering is a Key Step of a Project Project schedule 2- Basic Engineering The licensor is the unit s Architect Client project launch Licensor Selection Basic Engineering Detailed Engineering 1- Technical Consulting 4- Construction 3- Detailed Engineering Construction 24

25 Axens Innovative Approach Work together to develop a Licensor Selection CEED P F D Preparation of PID, Equipment P I D Preparation of lines, instruments Custom & Efficient Early Design During an Early phase of the Basic Engineering Design Basic Engineering Using qualitative & quantitative analysis to evaluate alternate schemes pros & cons C E E D Selecting the most appropriate options taking into account: Energy and/or Water constraints CAPEX, OPEX, flexibility/operability To ensure your project is built on solid process foundation and to provide the best possible return 25

26 CEED : Collaborative Phase & Powerful Decision-Support Tool 110 A lot of exchanges with customer in a tight schedule Number of meetings/ conf. call before H&MB / PFD finalization To propose various options evaluated using several criteria selected by the customer A powerful decision-support tool 90 Base +3 weeks Base Number of weeks before H&MB / PFD finalization 100 Basis Index for Base Case (Option A) CAPEX ENERGY Utilities Consumption WATER Consumption Base + 100% (x 2) Base CO 2 Emissions NPV (Net Present 15 years + Dedicated operability report for each option After licensor selection Typical With CEED Options A B C D Base Case Low Energy Very Low Energy Low Water 26

27 Conclusion Axens at the forefront of Innovation with Advanced Solutions & Technologies New processes Schemes improvement 27

28 Thank you! And see you on Axens Blog axens.net/blog 28