Polyethylene Terephthalate

Transcription

1 Polyethylene Terephthalate (PET) Table of Contents A Report by Nexant s CHEMSYSTEMS Process Evaluation/Research Planning (PERP) Program PERP Published April 2013 Section Page 1 Executive Summary FEEDSTOCKS FOR POLYETHYLENE TEREPHTHALATE PET PRODUCTION PROCESSES Transesterification of Dimethyl Terephthalate (DMT) Esterification of Purified Terephthalic Acid (PTA) Conventional Melt-Phase Polycondensation of bis-het Conventional Solid-State Polymerization (SSP) Polyethylene Terephthalate Technologies PROCESS ECONOMICS Regional Cost of Production COMMERCIAL MARKET ANALYSIS Global Consumption Global Supply Global Supply, Demand, and Trade Introduction INTRODUCTION TECHNOLOGY OVERVIEW Conventional Feedstocks Alternative Feedstocks TECHNOLOGY LICENSING STATUS AND MAJOR PRODUCERS

2 2.4 BUSINESS DEVELOPMENTS Major PET Acquisitions New PET Investments Developments in Bio-PET STRATEGIC AND BUSINESS CONSIDERATIONS PHYSICAL AND THERMODYNAMIC PROPERTIES SPECIFICATIONS HEALTH HAZARDS STORAGE AND TRANSPORTATION Chemistry TRANSESTERIFICATION OF DIMETHYL TEREPHTHALATE (DMT) ESTERIFICATION OF PURIFIED TEREPHTHALIC ACID (PTA) CONVENTIONAL MELT-PHASE POLYCONDENSATION OF BIS-HET CONVENTIONAL SOLID-STATE POLYMERIZATION (SSP) Conventional Melt Phase and Solid State Polymerization (SSP) ESTERIFICATION OF TEREPHTHALIC ACID (PTA) AND MONOETHYLENE GLYCOL (MEG) TO BIS-HET PRE-POLYMER MELT-PHASE POLYCONDENSATION SOLID-STATE POLYMERIZATION (SSP) RECOVERY OF MONOETHYLENE GLYCOL Commercial Technologies ALFA S GRUPO PETROTEMEX (GPT) - INTEGREX IntegRex ipet Summary Process Description AQUAFIL ENGINEERING Universal Polymerization Reactor (UPR ) Melt Polymerization Process BUHLER Solid High-IV Polycondensation (S-HIP) Process Combi-Crystal-PET (CC-PET ) Process CHINA TECHNOLOGY PROVIDERS

3 5.4.1 China Textile Academy (CTA) China Textile Industrial Engineering Institute (CTIEI) Huitong Chemicals Engineering Technique Joyou Chemical Technology Engineering Co. Ltd INVISTA PERFORMANCE TECHNOLOGIES (IPT) Melt Polymerization Process LURGI ZIMMER Direct High Intrinsic Viscosity (DHI) Melt Polymerization Process Direct Melt to Preforms MOSSI & GHISOLFI (M&G) Background Easyup Solid State Polymerization Process UHDE INVENTA-FISCHER Background Melt to Resin (2R-MTR ) Process Direct Processing UOP-SINCO Solid State Polymerization Process Recycling and Reprocessing Technologies for PET PHYSICAL SECONDARY OR SUPERCLEAN RECYCLING CHEMICAL RECYCLING OR TERTIARY RECYCLING CONVENTIONAL TERTIARY RECYCLING TECHNOLOGY Methanolysis Glycolysis Developing Technologies INTEGRATED UNDERWATER PELLETIZING SOLID STATE POLYMERIZATION PROCESS MONOETHYLENE GLYCOL RECOVERY & PRODUCTION OF TEREPHTHALIC ACID FROM RECYCLED PET (r-pet) FLAKES BIO-BASED PET Anellotech Inc. - Biomass Pyrolysis

4 7.3.2 Gevo s Fermentation Process UOP Virent Energy Systems, Inc BP Process Economics COSTING BASIS Investment Basis Pricing Basis Cost of Production Basis PROCESS COMPETITIVENESS Conventional PET Process via Melt/Solid State Polymerization Modified Melt Polycondensation Process without Solid Stating ipet IntegRex Process Superclean Process Based on Recycled PET PET Cost of Production Summary REGIONAL COST OF PRODUCTION ESTIMATES SENSITIVITY ANALYSIS Sensitivity to Feedstock Prices Sensitivity to Total Project Investment Sensitivity to Production Plant Capacity Sensitivity to Utility Cost Commercial Applications INTRODUCTION TEXTILE FIBERS Textile Fabrics Household Automotive Fiberfill Nonwoven Fabrics Carpet Facing Industrial Fibers

5 9.3 BOTTLE GRADE PET RESINS PET FILM AND SHEETS Regional Market Analysis GLOBAL OVERVIEW Consumption Supply Supply, Demand, and Trade NORTH AMERICA Consumption Supply Supply, Demand, and Trade WESTERN EUROPE Consumption Supply Supply, Demand, and Trade ASIA PACIFIC Consumption Supply Supply, Demand, and Trade Glossary References Appendix Page A Definitions of Capital Cost Terms Used in Process Economics... A-1 B Definitions of Operating Cost Terms Used in Process Economics... B-1 C PERP Program Title Index ( )... C-1 5

6 Figure Page 1.1 Global Melt Phase PET Consumption Global PET Melt Phase Demand, PET Recycling Code Major Process Steps for PET Production via Conventional Melt and Solid State Polymerization (SSP) Process How to Make 100 Percent Renewable PET Esterification of PTA and MEG to BIS-HET Polycondensation of BIS-HET Continuous Solid State Polymerization Monoethylene Glycol Recovery GPT Pipe Reactor PET Plant GPT Polycondensation Reactor Pipe with Vapor Offtakes Simplified Flow Diagram of ipet Process Block Flow Schematic of Buhler s S-HIP Process M&G s EasyUp Solid State Polymerization Process UIF ESPREE Tower Reactor UIF s Melt-To-Resin (MTR ) with optional Flake-To-Resin (FTR ) PET Glycolysis Process PTA Process from Recycled PET Effect of Water on PET Ethanolysis Percent Bio-Based PET Reaction Chemistry for Catalytic Fast Pyrolysis Gevo s Simplified Block Flow Diagram for Renewable para-xylene Reaction Chemistry of Synthesizing para-xylene from Glucose and or Fructose Overview of Virent s BioForming Platform for the Production of Biochemicals and Biofuels PET Bottle Resin Cash Cost of Production Comparison PET Bottle Resin Full Cost of Production Comparison PET Bottle Resin Regional Cash Cost of Production Comparison PET Bottle Resin Regional Full Cost of Production Comparison

7 8.5 Sensitivity of PET Cost of Production to Feedstock Prices Sensitivity of PET Cost of Production to Variation in the Total Project Investment Sensitivity of PET Cost of Production to Production Plant Capacity Scale Sensitivity of PET Cost of Production to Utility Prices Global Melt Phase PET Consumption Global PET Melt Phase Demand, Global PET Melt Phase Supply, Demand, and Trade Global PET Bottle Grade Supply, Demand, and Trade North America PET Melt Phase Supply, Demand, and Trade North America States PET Bottle Grade Supply, Demand, and Trade West European PET Melt Phase Supply, Demand, and Trade West European PET Bottle Grade Supply, Demand, and Trade Asia Pacific PET Melt Phase Supply, Demand, and Trade Asia Pacific PET Bottle Grade Supply, Demand, and Trade

8 Table Page 1.1 PET Bottle Resin Cost of Production Summary PET Bottle Resin Regional Cost of Production Summary Global PET Melt Phase Supply, Demand, and Trade Global PET Bottle Grade Supply, Demand, and Trade Typical Purified Terephthalic Acid (PTA) Product Characteristics Typical Properties of Fiber Grade Mono-Ethylene Glycol Licensors and Major Producers Strategic/Business Considerations Typical Properties for Unreinforced Polyethylene Terephthalate (PET) Commercial Specification of PET Typical Molecular Mass and Intrinsic Viscosity (IV) for Major PET Applications Melt-Phase Technology Configurations Solid State Technology Configurations M&G EasyUp Reference List UIF s MTR Project Reference Typical Specification of the Amorphous PET Feed DET and Monoethylene Glycol Recovered using Various PET Flakes FDCA Conversion to TA Prices of Raw Materials, Products, Utilities, and Labor Cost of Production Estimate for: PET Bottle Chips Resin Process: Conventional Melt/Solid State Polymerization Cost of Production Estimate for: PET Bottle Chips Resin Process: Conventional Melt/SSP using Bio-Derived Feedstock Cost of Production Estimate for: PET Bottle Chips Resin Process: Modified Melt Polycondensation Process without Requirement for Solid Stating Cost of Production Estimate for: PET Bottle Chips Resin Process: IntegRex ipet Production Cost of Production Estimate for: PET Bottle Chips Resin Process: Superclean Process Based on Recycled PET PET Bottle Resin Cost of Production Summary

9 8.8 Cost of Production Estimate for: PET Bottle Chips Resin Process: Conventional Melt/SSP; Brazil Cost of Production Estimate for: PET Bottle Chips Resin Process: Conventional Melt/SSP; China Cost of Production Estimate for: PET Bottle Chips Resin Process: Conventional Melt/SSP; Germany Cost of Production Estimate for: PET Bottle Chips Resin Process: Conventional Melt/SSP; Saudi Arabia PET Bottle Resin Regional Cost of Production Summary Polyester Fiber Applications Global PET Melt Phase Supply, Demand, and Trade Global PET Bottle Grade Supply, Demand, and Trade Capacities for PET Melt Phase in North America Capacities for PET Bottle Grade in North America North America PET Melt Phase Supply, Demand, and Trade North America PET Bottle Grade Supply, Demand, and Trade Capacities for PET Melt Phase in Western Europe Capacities for PET Bottle Grade in Western Europe West European PET Melt Phase Supply, Demand, and Trade West European PET Bottle Grade Supply, Demand, and Trade Capacities for PET Melt Phase in Asia Pacific Capacities for PET Bottle Grade in Asia Pacific Asia Pacific PET Melt Phase Supply, Demand, and Trade Asia Pacific PET Bottle Grade Supply, Demand, and Trade

10 CHEMSYSTEMS PERP PROGRAM The ChemSystems Process Evaluation/Research Planning (PERP) program is recognized globally as the industry standard source for information relevant to the chemical process and refining industries. PERP reports are available as a subscription program or on a single report basis. Contact Details: London: Dr. Alexander Coker, Manager, PERP Program Phone: + 44-(20) , acoker@nexant.com New York: Heidi Junker Coleman, Global Programs Support Manager Phone: , hcoleman@nexant.com Shanghai: Dr. Y. Larry Song, General Manager, Nexant China Phone: , ylsong@nexant.com Nexant, Inc. ( is a leading management consultancy to the global energy, chemical, and related industries. For over 38 years, ChemSystems has helped clients increase business value through assistance in all aspects of business strategy, including business intelligence, project feasibility and implementation, operational improvement, portfolio planning, and growth through M&A activities. Nexant has its main offices in San Francisco (California), White Plains (New York), and London (UK), and satellite offices worldwide. Copyright by Nexant Inc All Rights Reserved. 10