advanced technology in aromatics -...
TRANSCRIPT
© 2018 UOP LLC. A Honeywell Company All rights reserved. UOP 8315-0
Reducing Investment and Operating Cost
Advanced Technology in Aromatics Leo Bresler, Ph.D. Senior Manager
Aromatics
1 November 2018 Indian Petrochem 2018 Mumbai, India
1
Strong Fundamentals: pX is Cheaper to Produce than Buy
Para-xylene Demand: World-Wide • Para-xylene (pX): High value, transportable
chemical produced from heavy naphtha; used in polyester fiber & PET resin
• Demand growth 5% WW exceeds GDP
• China consumes more than half of all pX produced and imports more than half of what it consumes
• Even with large China build, new capacity cannot keep up with demand
– 2018 China imports: 16.2 MMTA
– 2028 China imports: 12.6 MMTA
• pX-naphtha spread $400-450 /Ton, can exceed $600
• Break-even w/ modern technology now < $200 /Ton
PX
, M
MT
A
China pX Supply Demand Balance
Source: PCI/UOP
0
5
10
15
20
25
30
35
40
45
2012 2014 2016 2018 2020 2022 2024 2026
Production Imports
World pX Supply Demand Balance
PX
, M
MT
A
2018-2027 CAGR = 5%
60%
70%
80%
90%
100%
0
10
20
30
40
50
60
70
80
2012 2014 2016 2018 2020 2022 2024 2026
Supply Demand Operating Rate
Source: IHS
150
250
350
450
550
650
Jan-14 Jul-14 Jan-15 Jul-15 Jan-16 Jul-16 Jan-17 Jul-17 Jan-18 Jul-18 Jan-19 Jul-19
N E Asia N W Europe
USGC
Break even
Regional pX-Naphtha Spread $/MT
India pX Value Chain – Capacity and Demand Growth
2
India pX capacity expansion lagging behind PTA, polymers growth
Source: PCI Q2 2018, HIS * - ‘14-’19 CAGR%
pX
PTA
Melt Phase
DMT Film
Resin
Staple
Filament
0
0
0
MEG
7.1%
3.4%
6.6%
9.7*%
’16-’21 CAGR%
6.7% 2%
‘18-’28 CAGR%
MM
TP
A
MM
TP
A
MM
TP
A
MM
TP
A
MM
TP
A
6.4
9.3
12.0
6.4
8.7
10.9
(0.6) (0.3)
0.2
2018 2023 2028
MM
TP
A
• *India currently [’17] net exporter of pX. Mainly to China & SE Asia country
• Due to fast growing demand by 2023 India will be in deficit of pX
Capacity
Import
Demand
Export
5.9 5.9
7.1
3.8
5.5
7.3
0.4*
(1.2) (1.5) 2018 2023 2028
5.5% 6.5%
‘18-’28 CAGR%
Adding New pX Capacity in India
3
Multiple factors support building pX in India
• Domestic demand: Fast growing domestic pX & derivative demand
• Slow supply increase: Capacity expansion slower than demand
• Feed stock availability: India’s exported ~ 200 kb/d naphtha in 2018 – Forecasted exports ~ 150 kb/d by 2025
• Location: India’s major export goes to China & SE Asia. So proximity to Asian consumers is a great advantage for India exporters
UOP’s Modern pX Technology (2018)
4
UOP: Long Tradition of Innovation and Commercialization
New economies
of scale
• ADS-47 adsorbent provides 25% higher capacity
• Proven in 18 commercial applications since 2011
• UOP adsorbent chamber and rotary valve designs help provide unmatched reliability at capacity
exceeding 2 MMTA
pX in a single train
Improved feed
utilization
• Latest generation CCR Platforming, Isomar, and Tatoray catalysts can deliver substantial
economic benefit
through improved yields, higher stability, and higher activity
Step change in
energy efficiency
• The Energy Efficient Aromatics Complex (EEAC) reduces energy consumption 25-40%
• Advanced heat integration
• 8 licenses since 2010
• 3 commercial
operations since
2014
Game-changing LD
Parex technology
• Reduces pX complex capital cost by 20%
• Builds on EEAC and achieves 20%
further energy
savings
• 13 new LD Parex plants licensed since 2016
Upgraded Catalysts
• UOP R-334 Platforming Catalyst − Increased aromatics, H2
& C5+ yields
− 6 operating units
• UOP I-600 EB Isom Isomar Catalyst − 2 operating unit
UOP TA-32 Tatoray Catalyst
− Improved activity & yields
− 10 commercial applications
Innovation Drives Value Creation
5
UOP’s Hallmark: Continuous Value Creation & Commercialization
UOP R-364 Platforming™ Catalyst
• ImpX for CCR Platforming
LD Parex Aromatics Complex Relaunch
– 20% CapEx reduction
– 20% lower energy than EEAC
– ADS-50 adsorbent
– 13 complexes in D/C, 20+ MMTA total capacity licensed
UOP R-284 Platforming™ Catalyst
• Improved aromatics yields
• 4 operating unit
• 25% higher capacity
• 18 commercial applications
UOP TA-30 Tatoray Catalyst • Max conversion of
heavy aromatics
• 9 operating units
UOP I-500 Isomar™ EB Dealk Catalyst
• Low xylenes losses / 11 commercial applications
UOP Tatoray™ PTD Process
• High Yield / 1 operating unit
2010 2011 2012 2013 2014 2015 2016 2009
+22% ROI +30% ROI Net Energy Required
Reduced by 1/3 vs. Best 2009 Designs
Additional 14%+ Energy Reduction
vs. Best 2010 Design
CAPEX and OPEX Reductions vs.
Best 2012 Design
+45% ROI
2017 2018+
1st start-up of Modern LD Parex
- 15-25% CapEx savings
- 20-35% lower utilities
- 20-40% less naphtha for same pX capacity
UOP ADS-43
MX Sorbex
Adsorbent
Toluene Methylation
UOP ADS-47 Parex™ Adsorbent
Energy Efficient Aromatics Complex
• 25-40% lower energy consumption
• 3 operating units
Technology Adoption Since 2010
6
Reliable Track Record Delivers Successful Market Adoption
• Rapid adoption of breakthrough technologies since 2010
• UOP capabilities are the keys to success:
‒ Continuous investment in state-of-art R&D to invent
‒ Leading engineering, manufacturing and service to commercialize
and execute
Description
Innovation
Year
Introduced
Commercial
Applications
by 2018
ADS-47 Parex Adsorbent 25% higher capacity 2011 18
I-500 EB-dealkylation
Isomar Catalyst
Higher xylene retention, activity and benzene purity
2013 11
TA-32 (30) Tatoray Catalyst Higher xylene selectivity
and heavy feed processing 2014 (2010) 10 (9)
EEAC Energy Efficient
Aromatics Complex
Flowscheme
25% less energy
consumption for PX
from reformate
2010 8
LD Parex Light Desorbent
Parex Flowscheme
20% less CAPEX and 40%
less energy consumption 2015 13
LD Parex: State of the Art
7
UOP’s LD Parex: Latest in a Line of Breakthroughs
13 world-scale
pX Complexes
20+ MMTA total pX capacity
licensed to date
Advantages over pDEB and
crystallization systems
• Light desorbent dramatically relaxes Parex feed fractionation need, enabling 40% less energy requirement
• Greatly simplified flowscheme
eliminates 20% of equipment and CapEx
• UOP has 40+ years experience
with light desorbent in 16 commercial plants
• UOP’s unique rotary valve
system is unmatched in simplicity and reliability
Enabled by UOP
adsorbent capability
• ADS-50 based on ADS-47 adsorbent technology
• ADS-47 commercialized in 2011 with 25% higher
capacity vs previous generation
• ADS-47 reliability
proven in 18 commercial plants
Modern UOP Aromatics Complex: LD Parex
8
20% Less Equipment than Conventional Design
• Uses Light Desorbent (Toluene)
• Desorbent taken as Raffinate Column overhead & Extract Column sidedraw
• A9 limit in XC overhead no longer a design constraint
• Overall complex still evaluated as a “system” to increase heat integration and reduce energy input
Isomar Unit
Raffinate
Benzene
A8 Rerun Column
Reformate Splitter
Heavy Aromatics
Reformate Light Ends
Paraxylene
Raffinate Column
Extract Column
Tatoray
Unit
ED Sulfolane Unit
Parex
Unit A8 Stripper
Heavy Aromatics Rectifier
Benzene-Toluene Column
Desorbent
LD Parex Delivers Lowest Cost pX Production
9
Conventional
EEAC • 3 in operation
•5 Design/Construction
LD Parex • 7 Design/Construction
2009 2010
2018
25% Energy Reduction
LD Parex
20% CapEx Reduction &
40% Energy Reduction
Energy Consumption
CA
PE
X
20% More Energy
Reduction
UOP 8315-9
Cost Advantage from Continuous Improvement: Reformate-based pX Complex
10
Continuous Innovation Drives Profitability
Reformate to pX, Asia feed, product, & energy prices 2017/8
590
610
630
650
670
690
710
730
750
770
790
2006 2009 2012 2015
CC
OP
, $
/MT
pX
UOP Pre-2005
UOP 2008
UOP 2015
UOP 2011
R-254/284/334
ADS-50
I-500/I-600 Isom
TA-30/32
LD Parex
R-264 based
ADS-37
I-300
TA-20HP
R-264 based
ADS-47
I-350
TA-30
Energy Efficient
(EEAC)
R-134 based
ADS-27 (2 train)
I-300
TA-5
$120/MT
Savings
2018
UOP 2018
Further Energy
Efficiency
Improvements
Reliability and Scale
11
Historical Knowledge of Entire pX Complex Key to a Reliable Design
• World-scale pX plant capacity
‒ 1975: 150 KMTA
‒ 1995: 400 KMTA
‒ 2015: 1,500 KMTA
‒ 2018: 3,000+ KMTA
• Increasing economies of scale without sacrificing reliability requires strong licensor capabilities
‒ Improved adsorbents and catalysts
‒ State-of-art design practices and validation
‒ Latest equipment design and fabrication methods
• Complex design is not only pX purification
– Limitations in any unit or equipment can bottleneck the entire production
– Lost production from a bottleneck can be very costly for modern plants
Example: 1/3 lost capacity of world-scale
plant for 2 years costs $120 M
UOP Parex Unit Sizes Across Time
Source: UOP licensed unit data
0
400
800
1200
1600
2000
1970 1975 1980 1985 1990 1995 2000 2005 2010 2015 2020
Ca
pa
cit
y,
KM
TA
pX
Commissioned
In Design / Construction
UOP Rotary Valve (RV) and Adsorbent Chamber Internals (ACI)
• Proven >99.9% reliable at all capacities
• Single train capacity reaching 3 MMTA pX
• ACI design optimizes flow distribution to maximize adsorbent performance
LD Parex Case Study Location: Middle East
12
Tremendous value added by latest generation technology
• Para-xylene Capacity: 1,400 kMTA
‒ National Oil Company
‒ Integrated refinery and petrochemicals plant
‒ 12 UOP process units for petrochemicals and clean fuels production
• State of the Art Facility, Utilizing Latest Technologies for Competitive Advantages vs. older complexes
‒ Optimized solution using LD Parex delivered nearly $2 billion in NPV
• Full Support Project Execution
– UOP managed entire engineering design
– Seamless FEED design
– Faster project execution
OpEx Impact of LD Parex Conversion
Heavy
Desorbent
Conventional LD Parex Savings
$/MT pX
Fuel Base Base - 12% 5
Steam Base Base - 44% 4
Electricity Base Base - 3% 0.5
p-DEB Base None 1
Total 10.5
LD
Par
ex D
rive
s D
ow
n
Pro
du
ctio
n C
ost
s
PX – Benzene Flexibility with Toluene Methylation
13
Existing plants can benefit from toluene methylation
• Selective alkylation of toluene with methanol to generate above-equilibrium pX xylenes
• Significant decrease in cost of pX
‒ 15-25% CapEx savings
‒ 20-35% lower utilities
‒ 20-40% less naphtha for same pX capacity
Revamp: 10% pX Yield Benefit
with Toluene Methylation
Co
mb
ine
d P
rod
uc
t Y
ield
, %
Base Case TM
PX
Benzene
Heavy Aromatics
C6 Raffinate
Light Ends
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
CCR Platforming™
Unit
Naphtha
Benzene
p-Xylene
Light Ends
A11+ Ref
orm
ate
Sp
litte
r
NHT
Tatoray™
Unit
To
luen
e F
rac
BZ
Fra
ctio
nat
ion
Isomar™
Unit
Deh
epta
niz
er
A9
Fra
c
Xyl
ene
Co
l
Parex™
Unit
Toluene
Methylation
Toluene
Heavy Aromatics
Methanol
Sulfolane
Raffinate
CH3 CH3
CH3
CH3OH +
Toluene Methanol para-Xylene
Summary: Modern UOP pX Complex
14
UOP’s Latest Designs Deliver Significant Value
LD Parex is the
latest in a line of UOP innovations, offering regional producers significant cost
advantage over pX
capacity in East Asia
The LD Parex design delivers 20% CAPEX savings and 40%
less energy and
carbon emissions
UOP has effectively scaled its pX technology, with successful and
proven operations
• >2.5 MMTA single train plants are in D/C
• New designs possible up to 3 MMTA
UOP technology is among the world’s
most reliable,
with virtually all licensed units operating well, at or above nameplate capacity since start-up
UOP’s commitment to innovation ensures our customers will be low
cost producers for
years to come
• LD Parex – Breakthrough Technology
• ADS-50 Adsorbent
• Toluene methylation
• Future Improvements
$
15
UOP 8315-15