polycarbonate technology opportunities for india · 15th november 2019 epc engineering &...

Polymers & Fibers

POLYCARBONATE

TECHNOLOGY OPPORTUNITIES

FOR INDIA

INDIAN Petrochem – 2019, Hotel The Lalit, Mumbai

15th November 2019

EPC Engineering & Technologies GmbH, Mr. Karol Kerrane

Polymers & Fibers

TECHNOLOGICAL SOLUTIONS FOR

POLYMER PRODUCTION &

CIRCULAR ECONOMY

GREETINGS FROM GERMANY

3

Henkel Henkel – EPC Group

ABOUT US

FAMILY> 300ENGINEERS &

SPECIALISTS

8LOCATIONS IN

GERMANY

140 YEARS OF

EXPERIENCE BUSINESS

4

5

TECHNOLOGY

LICENSING

ENGINEERING

SERVICES

PLANT

CONSTRUCTION

TECHNOLOGY LICENSING

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WE PLAY GLOBAL

> 1.000 PROJECTS

SUCCESSFULLY

DELIVERED

IN > 40COUNTRIES

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• The Only Competition for Innovation

Management

• The Most Important Award for Innovative SMEs

• A Club of Excellence for Germany's Innovation

Elite

The TOP 100 Honors the Most Innovative of Germany's Small

and Medium-Sized Enterprises.

EPC Engineering & Technologies GmbH

has been honored for the second time.

THE TOP 100 HAS BEEN ESTABLISHED FOR 30 YEARS

AND IS:

EPC ENGINEERING & TECHNOLOGIES

RANKS AMONGST THE TOP 100 GERMAN SME‘s

CLIENTS & PARTNERS

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POLYMER AND

CHEMICAL PLANT

TECHNOLOGIES

OUR EXPERTISE

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(PC) POLYCARBONATE / Polycondensation Plants

(PA6) POLYAMIDE 6 / Polymerization Plants

(PET) POLYESTER / Polycondensation Plants

(PAN) POLYACRYLONITRILE / Polymerization Plants

MODIFIED POLYMERS / PET-G, PCT, PBT, PBAT, etc.

RE-VAMPING & OPTIMIZATION

MASTERBATCH PLANTS

PILOT PLANTS

of existing Polymer Plants

for various Polymers

for Polymer Synthesis

(PA 6.6) POLYAMIDE 6.6 / Polymerization Plants

OUR PORTFOLIO IN POLYMERS & FIBERS

(EPS) EXPANDED POLYSTYRENE / Recycling Plants

including optimized Extraction Process

PLANT CONSTRUCTION

PROCESS TECHNOLOGY & GUARANTEES

ENGINEERING PACKAGE

KEY EQUIPMENT DELIVERY

SUPERVISION OF LOCAL ACTIVITES:

Engineering

Installation & Construction

Plant Start-up & Commissioning

FUNCTIONAL

TURNKEY

CONTRACT

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REFERENCE

PROJECTS

SOME EXAMPLES

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CHINA

2011 – 2015

OCC – Ningbo Oceanking Chemical Corp. (Daphoon)

PC POLYCONDENSATION PLANT

EPC´s melt transesterification process for simultaneous

production of different PC grades due to multiple finisher lines

(2 x 50 kta). Patented EPC variPLANT® technology.

LOCATION /

SERVICES BY EPC EPC /

CLIENT /

IMPLEMENTATION /

• Process Technology Package

• Basic Engineering Package

• Key Equipment Delivery

• FAT Quality Control

• Supervision of Installation,

• Supervision of Pre-Commissioning / Commissioning

• Basic recipe package

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Ningbo Zhetie Dafeng - the Complete Production Line

DMC DPC PC PC chips BPA

(production units ) (polycondensation) (final product handling) (unloading & melting)

Ningbo Zhetie Dafeng (Daphoon), the Complete Production Line

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• General Engineering

• General Contractor

• Construction and Assembling Supervision

• Commissioning Supervision

YANBU, SAUDI ARABIA

2007 – 2009

IBN Rushd Saudi Arabia (a SABIC affiliate )

CONVERSION OF 4 EXISTING PET

POLYCONDENSATION SYSTEMS

Conversion from textile fibers to food grade PET production

with a simultaneous capacity increase to 1,000 t/d.

LOCATION /

SERVICES BY EPC

CLIENT /

IMPLEMENTATION /

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• General Engineering

• Delivery of Equipment

• Construction and Assembling Supervision

• Comissioning Supervision

VOLZHSKY, RUSSIA

2007 – 2012

SIBUR I GAZPROM (Chimvolokno)

POLYESTER TIRE CORD PLANTProduction plant for polyester tire cord

LOCATION /

SERVICES BY EPC

CLIENT /

IMPLEMENTATION

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• Basic Engineering

• Detail Engineering

• Equipment Delivery

• Supervision

• Commissioning / Start-Up

• Training

CO2 PURIFICATION AND COMPRESSION

Capacity approx. 15 tons/h carbon dioxide (CO2) high

quality

LOCATION / BAKU, AZERBAIJAN

SERVICES BY EPC /

CLIENT / AzMeCo – Azerbaijan Methanol Company

IMPLEMENTATION / 2013 – 2014

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DAYUSHAN ISLAND, CHINA

2017 – ongoing

Zhejiang Petroleum and Chemical Co., Ltd.

260 KTA POLYCARBONTE PLANT

EPC’s melt trans-esterification process, simultaneous

production of different PC grades due to multiple finisher

lines (EPC Patented technology)

LOCATION /

SERVICES BY EPC EPC

CLIENT /

IMPLEMENTATION /

• Process Technology Package

• Extended PDP Engineering Package

• Key Equipment Delivery

• FAT Quality Control

• Supervision of Installation,

• Supervision of Pre-Commissioning / Commissioning

• Polycarbonate basic recipe package

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PC variPLANT®

Technology Licenses

More than 1 million tons per annum

which is a World Market Share of

> 20%, as per 2018 end

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Sources: GBI Research, IHS markit, EPC

MARKET FORECASTS & GROWTH TRENDS

Year 2000 2010 2020 2025 2028

Rest of World

China

Polycarbonate, Global Demand by Volume (Tons)

2000 – 2028

10 mio -

9 mio -

8 mio -

7 mio -

6 mio -

5 mio -

4 mio -

3 mio -

2 mio -

1 mio -

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Sources: BloombergNews May 2019

PC MARKET EVOLUTION 2018 - 2040

Over 40 Million

new electric vehicles

coming on the road

each year by 2035!

Electrical Vehicles (EVs) Growth Rates until 2040

23PC MARKET IN INDIA 2000 – 2020Polycarbonate Market India, Demand by End-use Segments (Tons)

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EPCvariplant 260 kta



PC MARKET IN INDIA 2000 – 2020Polycarbonate Market India, Demand by End-use Segments (Tons)

25PC GRADES AVAILABLE ON MARKET (according to MFR)

75

158

229

588

289

313

210

179

126

74

43

29

18

14

3 14

1 1 8 14

3 1 2 5 0 0 0

NU

MB

ER

OF

GR

AD

ES

IN

MA

RK

ET

MFR - MASS FLOW RATE (ASTM D1239 AND ISO 1133)

PC VARIPLANT TECHNOLOGY

>90% of PC Grades

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TRANSESTERIFICATIONPRE-

POLYCONDENSATION I

PRE-

POLYCONDENSATION II

FINAL FINISHING REACTOR

REACTOR 1 REACTOR 2 REACTOR 3

100 %

STAGE 1 STAGE 2

33.3 %

33.3 %

33.3 %

600 - 780 tons of PC per day

Flow diagram for 200 - 260 kta PC Plant with 3 finishing lines (1 – 3L)

EPC VARIPLANT POLYCARBONATE TECHNOLOGY

Plant Efficiency

Process Flexibility

+

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Ningbo Zhetie Dafeng - the Complete Production Line

DMC DPC PC PC chips BPA

(production units ) (polycondensation) (final product handling) (unloading & melting)

Ningbo Zhetie Dafeng (Daphoon), the Complete Production Line

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Integration with up-stream technology providers possible

POLYCARBONATE PRODUCTION PROCESSES

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Phenol

Acetone

Methanol

Carbon

Monoxide

DPC

Production

DMC

Production

HCL

Oxygen

*Typical Consumption Figures for

Ion Exchange Resin Catalyzed Process

Typical Consumption Figures McDermott (LUMMUS) DMC/DPC Technology

BPA Unit

DMC/DPC Unit

Typical Raw Material Consumption for 130 KTPA PC Production

CumeneBenzolMethyl

Cyclohexane ToluolNaphta

Propylene

LUMMUS

PCSpent Phenol

Spent DPC

BPA

H2O

CO2

H2O

Methanol+DMC

DPC

Anisole

Polycarbonate Production Unit

EPC VARIPLANT® Technology

130-260 KTA

Polycarbonate Chips

LUMMUS

BPA

Light and Heavy Bleeds Off-gas

30CIRCULAR ECONOMY

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Circular

Economy

MACRO & MICRO CIRCULARITY

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Management & Optimization

of

Effluent and Waste Streams

CIRCULAR ECONOMY

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Raw

Mate

rials

Utility Supply

(Steam, Electricity, etc.)

Gaseous

Solid

Liq

uidWaste:

Treatment

Process Production Plant End Product

Gaseous

Solid

Liquid

Burner /

Combustion

Emissions & Effluents

Waste Streams

CO2

Recovery

Possible

Thermal Energy

Recovery

Battery Limit (BL)

CIRCULAR ECONOMYThe Optimization and Re-use of Waste Streams: Thermal Energy Savings ≥15% Sustainability


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• Basic Engineering

• Detail Engineering

• Equipment Delivery

• Supervision

• Commissioning / Start-Up

• Training

PLANT FOR CO2 PURIFICATION AND

COMPRESSION

Capacity approx. 15 tons/h carbon dioxide

(CO2) high quality

LOCATION / BAKU, AZERBAIJAN

SERVICES BY EPC /

CLIENT / AzMeCo – Azerbaijan Methanol Company

IMPLEMENTATION / 2013 – 2014

Reference

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CO2 Recovery

This System can recover more then 90 % of the CO2 emissions from the PC plant off-gas (OG).

The CO2 purity will be more than 97%.

(possible max. purity 99.5%, if required)

Another advantage: optional use of the condensed water from the washer as demin water (DW).

HTM

Plant CO2

CO2

Recovery

PlantOG

OG

D

W

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CO2 Liquefaction

HTM Plant CO2 (g)

EnergieCO2

Recovery

Plant

OG

OG

Liquefaction CO2 (l)

D

W

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Possibilities CO2

Dry ice production

A PC Plant with 180 kta can produce 1.3 t/h

CO2 (s).

The CO2 (s) can be used to climatize processes in

laboratories.

The CO2 (s) can be used in the beverage industry.

The CO2 (s) can be used in the food industry (cold

chain).

1

2

3

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CO2-RECOVERY PLANT – CTK 600

For dry ice production capacity of 2 x 600 kg/h

LOCATION / AUSTRALIA

CLIENT / COMTECSWISS

IMPLEMENTATION / 2018 (under construction)

SERVICES BY CRYOTEC /

• Consulting

• Pre-Engineering

• Basic / Detail Engineering

• Plant Delivery

• Project Management

• Operation Start-Up

• After Sales Services

Reference

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Application for CO2

1. Industrial applications – e.g. MEG

2. Methanol etc.

3. Dry Ice

4. Medicine and Pharma industry

5. Food industry

6. Agriculture

1 2

3 4

5 6

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Integration with up-stream technology providers possible

POLYCARBONATE PRODUCTION PROCESSES

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EPC Supervision Service / Technical Assistance

EPC variPLANT®

Process Training

Plant SafetyTraining

Plant Operation Training

Plant Commissioning

Plant Pre-Commissioning

Plant Erection


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No restrictive license terms

No ongoing license fees

Produce the PC Grades you want,

Produce the PC Quantities you want,

Sell into the Global Market where you want

& when you want.

A one-off License Fee for EPC know-how

and technology license

Licensing Advantages


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TYPICAL CONTRACT STRUCTURE

1) Engineering Contract

▪ Extended PDP Engineering

incl. Application Software for DCS Process

plant control & SIS fail-safe software

▪ Technical Service

▪ License Fee

2) Equipment Delivery Contract

▪ Proprietary / key equipment

▪ Spare parts package


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Leading German Polycarbonate Technology Provider


Karol Kerrane & Michael Streng

CONTACT US

EPC Group is certified per DIN EN ISO 9001

EPC Engineering & Technologies GmbH

Dr.-Bonnet-Weg 1

99310 Arnstadt

Germany

Karol KerraneBusiness Development Director

T +49 3628 / 660 48 2900

E [email protected]

W www.epc.com

THANK YOU VERY MUCH FOR YOUR ATTENTION

polycarbonate technology opportunities for india · 15th november 2019 epc engineering &...

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