Innovations enabling new renewable and non conventional feedstocks for the petrochemical industry

Transcription

1 Innovations enabling new renewable and non conventional feedstocks for the petrochemical industry Edouard Fromentel Edouard Fromentel Strategic Studies and Business Intelligence Manager TTAL Petrochemicals

2 Polymer demand continue to growth while oil production will level off World Demand, Index Crude il application by sector 900 Average 800 Growth Polymer Demand 700 Rate GDP 5,6 % ,2 % 2.1% ,5 % il Production GasProduction Mb/d Electricity Production Redidential / other industries Transportation Fuels Petrochemicals Source : TTAL il will preferably be used for the production of Base Chemicals and transportation fuels, domains where its replacement by alternative energy sources is the most difficult 2 JA Atelier 10 - E. Fromentel - Innovations enabling new feedstocks for the petrochemical industry

3 Polymer demand keeps growing while oil production will peak : inducing the need for new feedstocks and new technologies Feedstock sources for the conventional petrochemical building blocks (1) Mton of monomers Mt 500 Methanol An expected 30 Mton of light olefins should be produced in 2030 using Methanol to lefins technology, with most of the plants located in China and using coal feedstock Naphtha & heavier Ethane LPG Renewables (2) An expected 7 Mton of monomers should be produced from renewable feedstocks, with the majority issued from the dehydratation of bioalcohol (typically bio-ethanol) Notes (1) lefins (Ethylene, Propylene,C4s) & Aromatics (Benzene, Toluene, Xylenes) (2) By construction, this chart excludes all bio-based based plastics (such as PLA) which are not produced from a conventional (but bio-based) monomers Source : TTAL 2030 scenario 3 JA Atelier 10 - E. Fromentel - Innovations enabling new feedstocks for the petrochemical industry

4 New pathways to conventional Ys The Methanol To lefins technology : filling the gap between een Existing Xs (Gas, coal feedstock) And existing Ys (mainly light olefins) 4

5 New pathways to conventional Y s X To Y Ethylene MT Propylene Natural gas Coal Petcoke Residu Biomass Natural oils Reforming: SMR/ATR syngas Reforming: gasification xygen removal Methanol DME Fischer-Tropsch hydrocarbons Diesel Lubes LPG Naphtha MTP MTG Steam cracking Propylene Gasoline r BTX Gasoline Ethylene Propylene Butadiene BTX ydrous bioethanol Dehydration Ethylene 5 JA Atelier 10 - E. Fromentel - Innovations enabling new feedstocks for the petrochemical industry

6 Methanol To lefins and CP (lefins Cracking Process) technology presentation Natural gas Ethylene Coal Biomass Syngas Methanol MT + CP Propylene C 4+ purge % weight lefin yields 100% 80% thers 60% Propylene 40% 20% Ethylene 0% TTAL MT / CP demonstration plant in Feluy Naphta Cracker MT MT + CP 6 JA Atelier 10 - E. Fromentel - Innovations enabling new feedstocks for the petrochemical industry

7 MT : from the Pilot unit to the industrial scale investment Aim: prove a new technology for polymers production from methanol to diversify the source of plastic feedstock (coal/petcoke, natural gas..) Pilot plant in Feluy integrating the UP/ydro Methanol To lefins (MT) process with the Total Petrochemicals lefin Cracking Process (CP) in order to produce olefins from methanol. The connection to a polymerization pilot unit is a world first and will allow acid test of the produced olefins quality 45 million investment. Total Group s second-largest current research project istory : kick-off: 12/2005; start-up: 12/2008; technical validation: 12/2009 Industrial upscaling : TTAL Coal to Polyolefins in China / Inner Mongolia has been announced in Nov. 2010, with our chinese Partner (KPI, an electricity producer). Project cost : 4 to 5 B$ - Targeted polyolefins production : kt 7 JA Atelier 10 - E. Fromentel - Innovations enabling new feedstocks for the petrochemical industry

8 Worldwide industry development around the MT technology Current China monopoly on MT technology implementation : Today : 3 CTP (Coal to Polymers) complex have started since 2010 MT technology derived from Lurgi or Chinese design institute Typical capacity of 500 kt of light olefins Most of them still in the learning curve, running at reduced d capacity A 4 th plant is in construction and should start up in projects are at the engineering stage, and ca 8-10 in the initial feasability phase. China gathers all critical factor for a succesfull MT project implementation Competitive CAPEX : CTP concept is highly CAPEX intensive (especially for the Gasification phase) Competitive feedstock : Abundant coal reserves Structurally short and fast growing petrochemical market : with typically 8 to 10% per year demand growth rate for polyolefins No integrated Gas to Polymers project has been launched so far, but it should be part of a second wave of MT projects 8 JA Atelier 10 - E. Fromentel - Innovations enabling new feedstocks for the petrochemical industry

9 Global Bio-based polymers review What is biomass? Key market drivers for renewable feedstocks Green polymer mapping & production outlook 9

10 What is biomass? Nutritional reservoir in plants C 2 Mono/di-meric sugars: sugar cane and sugar beets C 2 C 2 C 2 C 2 C 2 C linkage 1G Starch: corn, wheat etc Branched and amorphous Easy digestible by enzymes -1-4 linkage Food Lipids: rapeseed, soybean, palm etc C 2 C Structural role in plants C years Cellulose: [30-50%] Crystalline glucose polymer ighly stable (e.a. cotton) Difficult chemical hydrolysis y Special cellulase enzyme to depolymerise C 2 C linkage C 2 emi-cellulose: [15-30%] eteropolymer of C 5 and C 6 sugars with acetyl-substituents Branched and amorphous Easily to hydrolyze Lignin: [10-25%] Complex aromatic structure Resistant to biochemical conversion Complex depolymerisation C 3 C 3 2G Non-Food 10 JA Atelier 10 - E. Fromentel - Innovations enabling new feedstocks for the petrochemical industry

11 Innovations to meet market demand: Emergence of bio-feedstocks A push of fossil to renewable feedstocks lefins & Aromatics feedstock sources Key drivers to renewable feedstocks: Availability of biomass Technologies becoming available, with improved economics thanks to high crude oil perspective and increased pressure from C2 taxes and locall or regional carbon trading regulations A pull from stakeholders to renewable feedstocks Bio-polymers investment momentum driven by: End-user awareness for green products and renewable sources. Strong objectives / long term commitments from Brand owners towards green products Pull from legal & tax environment, increased R&D grants. New energy / C2 environment, market forces and technologies are driving the growth of renewable feedstock in the chemical industry (which is not subject to any kind «biofuel» type of mandate) 11 JA Atelier 10 - E. Fromentel - Innovations enabling new feedstocks for the petrochemical industry

12 Green / Bio polymer mapping Renewable content 100% bio based 100% bio based & «Bio-polymers» generally refers to Traditional polymers fully biodegrable polymers produced (fully / partially) from Cellulose based polymers a renewable feedstock 100% bio Polyethylene Starch based polymers PA Interest for the biodegradability fully bio Polyamides PLA property is fading as it is no more considered as a sustainable end of life option for plastics, while renewable Partially bio based : Partially bio based & carbon content and global footprint / PTT Bio 1,3 PD fully biodegrable LCA (Life Cycle Analysis) concepts are PUR Bio Polyols from gaining g success PET Bio MEG PLA or starch blends with PVC Bio Ethylene biodegradable polyesters The «Green polymer» designation is now widely used by all stakeholders as BI MNMERS this term, used for green marketing Biodegradability purpose, is usually mixing different sustainable development concepts such as : Traditional polymers Fossil based / Biodegradable The renewable carbon content Polyolefins PE,PP PP with agents The biodegrabability concept PS, PVC Polyesters "Modified" polyesters : The recyclability options Polyurethanes (PUR) PBAT, PBS, PCL, etc The incorporation of recycled polymer into a virgin product Crude oil, gas, coal JA Atelier 10 - E. Fromentel - Innovations enabling new feedstocks for the petrochemical industry

13 World bio-polymer market development perspectives 2011 Bio-polymers market 2020 Bio-polymers market 880 Kta 4. 8 Mton ca. 0.3% of total demand for plastics ca. 1% of total demand for plastics thers Starch-based PA PLA Polymers from bio-sourced monomers Bio-polymer to grow 20% per year til 2020 ighest growth rates foreseen for PLA and bio-based polyolefins Starch-based PA thers PLA Polymers from bio-sourced monomers Source : Pira study Polymers from bio-sourced monomers Currently bio-ethylene for PE and MEG, tomorrow will most likely include Bio-Propylene derivatives Easy substitution of oil-based counterpart but no additional properties other than renewable origin. PLA (PolyLactid Acid) The very first bio-polymer produced at an industrial scale (with the Natureworks plant start up in 2003) After the initial years of discovery by the market players (convertors, brand owners..), PLA is now gaining strong market momentum thanks to the heavy R&D efforts occurring in term of applications Starch-Based Today the most important bio-plastics (usually in blends to improve mechanical properties). Mainly used for its biodegradable properties in packaging, but poor mechanical properties. PAs (The PolyydroxyAlkanoates family) Similar to PLA but directly produced into micro-organisms. Wide range of potential properties. Current high production costs with difficult start-up of the first industrial scale plants. 13 JA Atelier 10 - E. Fromentel - Innovations enabling new feedstocks for the petrochemical industry

14 New X to Y routes being developed Innovation in Bio-ethanol Dehydratation process Development in new PLA production process and polymer application technologies 14

15 New Bio-alcohol dehydratation and PLA production technologies will be the key biopolymer market growth drivers Renewable feedstocks Corn, Tapioca, STARC wheat,.. Lactid Acid 100% bio based and biodegradable polymers PLA Beet Sugar Cane SUGAR Fermentation Development of micro organisms 2 nd Gen. CELLULSE Alcohol (Ethanol, Propanol,...) Dehydratation to Bio Monomer Traditional polymers, but from renewable sources BioPE, BioPP... Existing plant and project are using 1 st generation biomass feedstock (sugar cane, beets, corn..) but should be fully compatible with cellulosic based feedstock, when such supply will be available at a competitive production cost. 15 JA Atelier 10 - E. Fromentel - Innovations enabling new feedstocks for the petrochemical industry

16 Key drivers for developing a new Bio-ethylene technology Very high market demand for bio-based ethylene derivatives Confirmed perspective of continuous high energy prices & increased C2 cost pressure Advantages of the Bio-based monomers approach : for the producer, possibility to re-use existing polymer plant for the convertor, 100% identical polymer specification and performance : risk free and instantaneous substitution from the fossil based material Possibility to apply similar dehydration technology to other bio-alcohol (bio propanol, bio isobutanol...) when they will be available at large scale amount and competitive pricing Technology compatible with the ultimate plastic development goal which is to use 2 nd generation bio feedstock (cellulosic ethanol) Available technologies on the market had poor ethylene selectivity and energy efficiency Joint Development Agreement signed between TTAL, IFP and Axens (March 2011) TTAL brings its catalyst development expertise and pilot plant facilities with IFP EN to develop the new associated dehydration process scheme Axens in charge of the technology licensing Brazil US EU 16 JA Atelier 10 - E. Fromentel - Innovations enabling new feedstocks for the petrochemical industry

17 PLA technology development : the Futerro example 2 nd generation feedstock (biomass / ligno-cellulose) Sugar cane - Sugar beets Sugar Futerro 1500 t/y PLA pilot plant in Escanaffles Corn - Tapioca - Wheat Starch Process development JV TTAL - Galactic founded in Sept M global investment 1500 ton/yr PLA demonstration plant started successfully in April 2010 Lactic Acid Lactide PLA Polylactic Acid Product development Improving the heat and impact resistance of the «native PLA» through : macromolecular structure improvements : stereocomplex & stereoblock developments Compounding formulation with other polymers Nanoalloy technology New additives and nucleating agents, etc 17 JA Atelier 10 - E. Fromentel - Innovations enabling new feedstocks for the petrochemical industry

18 New pathways to non conventional Ys Emergence of new families of bio-based chemical building blocks 18

19 Mapping of main bio-routes by the US Department of Energy 19 JA Atelier 10 - E. Fromentel - Innovations enabling new feedstocks for the petrochemical industry Source :

20 New bio-based building blocks attracting the most R&D efforts While being mostly produced from through a fermentation process, the various building blocks differentiation comes from their number of carbon dicarboxylic acids. The new intermediates driving today the highest interest are : In the C3 family (other than the previously mentionned Lactid Acid ) : 3-ydroxypropionic yp p acid (3 PA) production leading, among others, to bio 1,3 propanediol p and bio acrylic acid Glycerol feedstock (which is a also by product of the biodiesel production) for a bioepichlorhydrin production, being ultimately used for bio epoxy resins production In the C4 family : the succinic acid, targeting the production of a fully bio-based PBS (Polybutylene succinate) and other derivatives As for existing biopolymers, many blends and / or co-polymerisation developments are underway These few bio-plastics examples are a good illustration of the current exponential development of the «green chemistry» which is happening in all sectors of the chemical industry (ie polymers, but also consumer and specialty chemicals, agro-chemicals chemicals, healthcare products, etc..) 20 JA Atelier 10 - E. Fromentel - Innovations enabling new feedstocks for the petrochemical industry

21 21 Conclusions

22 Innovation around the Sugar & Syngas platforms are driving the emergence of new renewable and non conventional feedstocks Sugars / Starch Sugar Platform Fermentation 1 st generation Dehydration C 2 Alcools + C2 to Monomers Polymerisation Lactic acid 2 nd generation to PLA Ligno-cellulose (incl.agr waste) MSW: solid municipal waste SRF: Solid recovered fuel Biotechnologies Waste plastics Syngas Platform Alcools + C2 Dehydration to Monomers MSW/SRF Gasification reforming Syngas C/2 Coal / Petcoke Natural gas Methanol MT/CP Ethylene Propylene 22 JA Atelier 10 - E. Fromentel - Innovations enabling new feedstocks for the petrochemical industry

23 Innovation not only at the feedstock level, but addressed through the whole life-cycle Feedstock Renewable origin Process Reduced environmental impacts - Methanol To lefins (MT) - Bio-Ethanol To Bio-Ethylene - PolyLactic Acid (PLA) - Syngas / Biotech - Waste (Plastics) Specific energy Reduction programs Use phase Reduced environmental impacts Reducing environmental impacts for our customers End-of-life Sound and efficient options - Actions in line with waste hierarchy - Life cycle thinking Reduce Reuse Recycle Energy recovey Landfilling 23 JA Atelier 10 - E. Fromentel - Innovations enabling new feedstocks for the petrochemical industry