STAR process® technology - Conference · PDF fileSTAR process® Block Flow Diagram...

23 - 24 January 2017 | The Ritz Carlton, Manama, Bahrain

thyssenkrupp Industrial Solutions | Martin Cosfeld

STAR process® technology

Robust on-purpose propylene production technology

Introduction

Who are we?

thyssenkrupp Industrial Solutions – Business Unit Electrolysis and Polymers 3 | 23-24 January 2017 | MERTC, The Ritz Carlton, Manama, Bahrain | STAR process® - Robust on-purpose propylene production technology | Martin Cosfeld

Components

Technology

Elevator

Technology

Industrial

Solutions

Materials

Services

Steel

Americas

Steel

Europe

Sales [mn €]

6,753 7,208 6,256 14,254 1,773 8,697

EBIT² [mn €]

313 794 424 206 (138) 492

Employees

29,627 51,335 19,388 20,226 3,725 27,601

thyssenkrupp – Business Areas Key indicators – fiscal year 2014/20151

1. Continuing operations (after reclassification of Steel Americas) | 2. Adjusted before consolidation

thyssenkrupp AG Sales: 42,778 mn € | EBIT adj.²: 1,676 mn € | Employees: 154,906


thyssenkrupp Industrial Solutions Process Technologies – Outstanding technology portfolio with full process chain offerings

Uhde technology Core licences important intermediate stage

Ethylene dichloride

Methanol

Hydrogen

Chlorine

Caustic soda sol.

Nitric acid

Urea

Ammonium nitrate

PVC

Polyurethane

Ammonia

Lube oil, waxes

Chlor-alkali electrolysis

Coking plant

Ethylene

Bioethanol

Coke Gasification/ power plant

Xylene

Toluene

Benzene

Oil refinery

Propane

dehydrogen.

Ethylene oxide Ethylene glycol

Natural gas/ Shale gas

Crude oil

Coal

Salt

Renewable resources

Propylene oxide

Terephthalic acid

Caprolactam

Fischer-Tropsch synthesis

Lactic acid Polylactic acid

Formaldehyde

Methanol to Gasoline

Sugar Succinic acid Refining/

fermentation

Steamcracker

Hydrogen

Propylene

Gasoline, diesel

Polyethylene

Polypropylene

Polyester

Polyamide

Urea/Formaldehyde

Granulation

EnviNOx®

Granulation

Vinyl chloride

Steam reforming

Autothermal

reforming

Feedstocks Intermediates

Adhesives, synthetic resins

Fertilizers

Plastics

Electric power

End products

Steel

Fuels

Lubricants, waxes

Fuels

Bioplastics

Fine chemicals

STAR process®

Light olefins production via dehydrogenation of propane and butanes


STAR process® Market view: On-purpose production of propylene growing

Demand

• Mainly driven by growing demand for Polypropylene (PP)

• Other products are Propylene Oxide, Cumene, Acrylonitrile, Acrylic Acid, Oxo Alcohols

Supply

• Demand for propylene outpaces supply from conventional sources (Steam Cracking, Fluid Catalytic Cracking)

• Refinery economics & improved fuel efficiency affecting supply from refineries

Conclusion

• On-purpose production of propylene required

• Share of on-purpose technologies growing from 7% in 2000 to >30% in 2022

Source: IHS, 2013


STAR process®

Brief history & references

since 1960s: Development by Phillips Petroleum

1992: Commissioning of first commercial STAR plant, Coastal Chem, Wy, USA

1994: Commissioning of second commercial STAR plant, PBA, Ensenada, Argentina

1999: Technology and catalyst acquired by TK Uhde incl. all patents, rights

2000-2003: Enhancement of technology

2007: LSTK contract: first commercial PDH plant based on STAR process®

2009/11/13: 3 contracts: License & basic engineering incl. supply of proprietary equipment and catalyst plus technical assistance services

Coastal Chemicals

• Wyoming, USA

• Commissioning in 1992

• 100,000 t/a Isobutylene

Formosa Plastics Corporation

• Texas, USA

• Commissioning in 2018/19

• 545,000 t/a Propylene

Polybutenos

• Argentina


• 40,000 t/a Isobutylene

EPPC

• Egypt



MEPEC

• Iran



SFPC

• Iran




STAR process® Reaction chemistry (Dehydrogenation)

•C3H8 C3H6 + H2 (+ 124 kJ/mol)

•C4H10 C4H8 + H2

Main reaction

•CH4, C2H4, C2H6, CO2 By-products

•Cracking of hydrocarbons (HC) Coke formation

•C + H2O CO + H2

•C + 2 H2O CO2 + 2 H2 Coke conversion


STAR process® Block Flow Diagram (typical)


STAR process® Uhde Reformer References

• Fixed bed reactor

• More than 70 steam reformers since 1966

• Simple, reliable and robust in operation

• Commercial reformers operate over a wide range:

Ammonia @ 40 bar 780 - 820 °C

Methanol @ 20 - 25 bar 850 - 880 °C

Hydrogen @ 20 - 25 bar 880 °C

Oxogas @ 9 - 12 bar 900 °C

Olefins (STAR) @ 5 - 6 bar 570 - 590 °C

EPP

Port Said


STAR process® STAR catalyst®

o Commercialised

o Platinum promoted basic calcium and zinc aluminate

o Stable in presence of steam and oxygen at high temperature

o High selectivity at near equilibrium conversion

o Regeneration is simple and sustainable

o No chemicals for catalyst activation or coke suppression Reduced OPEX; no

environmental issues

o TKIS supplies certified catalyst

o Same catalyst for PDH and BDH

o Continuous catalyst development program on-going


STAR process® Are your real costs under the surface?

OPEX

CAPEX

Operability

• Feedstock

• Energy

• Cooling water

• Catalyst

• Chemicals / adsorbents

• Process License + PDP

• Engineering

• Procurement

• Construction

• Other costs (land, etc.)

• Safety / environment

• Loss of production

• Reputation

• Quality

• Delivery issues

OPEX

CAPEX

Operability


STAR process® CAPEX advantages: Lowest investment on the market

• Lowest catalyst inventory / reactor volume on the market

• Simple in-situ regeneration Highly efficient reaction section

• Lowest compression costs on the market

• Less MA/PD and C5+ byproducts High reaction operation pressure / low

operation temperature

• Standardized air compressor design can be applied

• E-motor or steam turbine drive may be used Low regeneration air demand


STAR process® CAPEX advantages: Do not only look on single-pass conversion - an example for the three most expensive units

• Cheapest reactor system on the market

• Only process with direct heating of the reaction zone Reactor / catalyst volume

• Smallest compressor on the market

• High suction pressure leads to low compression ratio and low inlet volume flow

Raw gas compressor

• Reactor conversion almost irrelevant for C3 splitter dimensions

• Position of feed tray depends on propylene concentration

• Reflux ratio / reboiler duty dominated by propylene product purity

C3 Splitter


STAR process® Operability advantages

• No moving catalyst or hot switching valves

• Simple and robust operation less maintenance Fixed bed reactor type

• Independent parallel reactor trains • Olefins production without Cold Box possible

High availability and reliability

• Shorter re-start from „hot stand-by“

• Demonstrated plant availability of >98% Shortest start-up and overall shut-down

time


STAR process® Case study: Feedstock and avalability dominate plant profitability

Base Case UOM Value

Capacity kta 450

Depreciation %/a 5

Operating Hours h/a 8000

Propane (100% basis) USD/ton 500

Propylene USD/ton 1100

105

115

120

100

110

95

90

0

10% 5% 0% -5% -10%

Pro

fit [%

of b

ase

ca

se

]

Change of parameter

Production (Availability)

Investment Costs

Feedstock costs

Utility costs

Integration Options

Highly efficient plant concepts due to integration of PDH with downstream technologies

and utilities

PDH

PO / PP

Utilities


Integration Options HPPO process

License jointly by Evonik & thyssenkrupp

Catalyst by Evonik

Engineering by thyssenkrupp

H2O2

PO producer

HPPO

Less costs, less space, less energy & no co-products

Advantages of technology Economic benefits

• Co-product-free process

• Combination of efficient heat transfer with an almost ideal plug-flow characteristic through specially designed epoxidation reactor

• High-performance catalyst with a long lifetime

• Chlorine-free process

• Optional use of polymer-grade or chemical-grade propene feedstock

• Lower capital investment and energy consumption compared to state-of-the-art PO technologies

• High specific yields resulting in low feedstock consumption

• Stand-alone technology: no market dependency on co-products


ID257

First Polymer Plant built in 1959

More than 90 polyolefin plants world-wide

- high pressure processes

- suspension processes

- fluidised gas phase processes

- stirred gas phase processes

- multizone processes

Contracts for polyolefin plants covering capacities of over 10 million mt/y have been awarded to TKIS up to now.

Focus on technology (Study, PDP and FEED preparation), EPC competencies, experience in revamps and plant

optimizations

Integration Options Polymer Experience

Product Projects Technologies

HDPE slurry 35 1

LDPE 22 5

LL/MD/HDPE 5 4

PP 30 4

PVC (S+E) 37 3


ID257

o Licensor for PDH & PO Technology

o Engineering and operation know how in PDH, PO and PP

o Fast track project delivery (PDP and FEED in parallel for PDH, PO and PP)

o Conceptual engineering for PDH, PO, PP, offsites and utilities

o Single point of contact (engineering for all plants and facilities out of one hand; PP license

can be aquired via TKIS)

o EPC capabilities with local setup and global sourcing

Integration Options Contribution to a successful petrochemical investment


Integration Options Reference EPP PDH Plant – EPP PDH/PP site view

Location: Port Said, Egypt

Description of the complex:

• PDH Plant: 350,000 MTA Propylene (TKIS STAR

process)

• PP-Plant: 350,000 MTA Polypropylene (Basell

Spheripol Process)

• Offsites & Utilities Plant: Steam Generation, Cooling

Tower, Refrigeration Unit, Air Separation Unit, H2

Generation, Storage, Flare, etc.

• Feed: Propane, Natural Gas, Raw water, Electricity

• Target Products: Bulk Stable Fibre (carpets); Film;

Raffia

Project Scope: EPC LSTK including license for PP and PDH

Savings due to integration: approx. 5% of TIC

Summary


Summary Reliable, safe and low investment costs

o Operation in presence of steam reduced coking prolonged reaction cycles

o Reactor system: Highly efficient, commercially proven top fired reformer

o High availability / reliability:

a) Fixed bed reactor principle

b) Simple in-situ regeneration

c) Production without cold box possible

d) Independent parallel reactor trains

e) Short start-up and overall shut-down time

o Integration with PP or PO plants leads to more viable projects

o Execution out of one hand (PDP + EPC) leads to shorter project time single point of responsibility


Poll question

Were is the major market for on-purpose propylene production?

a)MENA

b)USA

c)Canada

d)Asia (esp. China)


Thank you!

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