cativa bp
DESCRIPTION
Methanol carbonylationTRANSCRIPT
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Mr. Jon Horler
Acetyls Project & Engineering ManagerBP
A Chartered Chemical Engineer, Mr. Jon Horler has worked for BP for 25years and leads a team responsible for the delivery of technology andengineering in support of BPs proprietary package for the manufactureof Acetic Acid.
Part of his role is also to provide project management during conceptselection and early stage development for licensing opportunitiesworldwide.
Mr. Jon has previously worked on major projects in the UK, China,Taiwan, Malaysia, Korea and India.
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Overview of Acetic acid Production
Through Petcoke Gasification
IOCL Petrochemicals Conclave
18th
March 2013
Jon Horler, Projects and Engineering Manager
Acetyls and Aromatics Technology
2013 BP Chemicals Limited All rights reserved
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Outline
Overview:
What is Acetic Acid
Key Uses of Acetic Acid
Chemistry
Feedstock Choices
Acetic Acid Technology
Sources of Project Value
2013 BP Chemicals Limited All rights reserved
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What is Acetic Acid?
A very important chemical
A key raw material for the production of a wide number of products we use in our everyday
lives
Do you know that acetic acid in its very dilute form is vinegar that is consumed or used in the
manufacture of food products?
Acetic acid is involved in the manufacture of other items you'll find in your shopping basket,
such as washing powder, drink bottles and food
packaging
With just 1 tonne
of acetic acid our
customers can
make 38,000 jars
of pickles*
*BP Internal Data
2013 BP Chemicals Ltd All rights reserved
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Key uses of Acetic Acid
Vinyl Acetate Monomer (VAM)
Paint, adhesives in furniture or floor covering, manufacture of clothes, shoe soles, juice cartons and cheese packaging,
manufacture of safety glass for car windscreens
Purified Terephthalic Acid (PTA)
Plastic containers for beverages, food and electronics, apparel, home textiles, carpets and industrial fibre products,
audio and video recording tapes, photographic films and
labels
Acetate Esters (Ethyl Acetate, Butyl Acetate)
Solvent in printing inks, laminating adhesive in flexible packaging and plastic films. Also used as solvent in paint,
varnishes, resin coatings and nail polish remover
Acetic Anhydride
More than 75% made into cellulose acetate found in filter tow, textiles, photographic and x-ray films
Also used in pharmaceuticals such as aspirin and paracetamol
2013 BP Chemicals Ltd All rights reserved
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Acetic Acid Technology Evolution
CATIVA gives advantages across all
key project criteria:
Capital - simplification of flowsheet results in lower project costs for new
build plants
Variable Cost - patented catalyst technology and subsequent reduced
energy requirements result in lower
operating costs
Cash Cost / Reliability - less equipment items to maintain mean
lower annual maintenance spends
and less downtime
Scale - potential to build at scale to suit market demands improves
capital efficiency
Fully Built-up Cost - all of the above have a positive impact on overall
project economics and long term
sustainable operations
Feedstock
changes
Process
changes
Time
Methanol carbonylation Hydrocarbon oxidations
Cost estimates are based on generic models
0
20
40
60
80
100
120
Ethylene Naphtha Rhodium Rhodium / lithium Iridium
Pro
duct
ion c
ost
[in
dex
ed t
o e
thyle
ne
pro
cess
to
tal
cost
= 1
00
]
Cash cost = variable + fixed Capital-related costs=depreciation + return on investment
2013 BP Chemicals Ltd All rights reserved
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Methanol Carbonylation:
A C1 route to Acetic Acid
Natural Gas
Coal
Pet Coke
Naphtha
Light HCs
Heavy HCs
Biomass
.
Syngas
(CO + H2)
Purify CO Compress
CO
Pure
CO
Methanol Distribution Methanol
(CH3OH)
Acetic Acid
(CH3COOH)
CO must be generated locally
MeOH purchased as a globally traded commodity
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2013 BP Chemicals Ltd All rights reserved
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Feedstock Selection In India
Main issues associated with accessing attractive CO economics are:
High energy costs. Investment in lower capital Nat Gas/Fuel Oil based Syngas plants (eg SMR/POX) have higher variable costs
Investment in Coal/Petcoke based Syngas plants (Gasification) delivers much lower energy / variable cost but carries a much higher capital
cost burden and is dependent on scale and integration opportunity
For a methanol carbonylation production, feedstock access
for competitive CO
production cost is key to the
Acetic Acid value chain
Re
lativ
e E
ne
rg
y C
ost
Feedstock Options
2013 BP Chemicals Ltd All rights reserved
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Ulsan, South Korea
SSBP: AA , 51%
Nanjing, China
Byaco: AA , 50%
Shanghai
Head office
Kertih, Malaysia
BPPA: AA, 70%
Chongqing, China
Yaraco: AA &
Esters , 51%
Kuala Lumpur
Commercial office,
Rest of Asia
Taiwan
FBPC: AA, 50%
Naperville/Cantera
Commercial Office USA
Hull, UK
Europe Commercial Office and
Production
AA and Anhydrides
Texas City
AA
Acetyls sites
Commercial/Sales offices
% BP share of JVs
BP Acetyls Global Experience
2013 BP Chemicals Limited All rights reserved
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CATIVA Process Flow Diagram
Vent Gases
To Flare
Acetic Acid
Product
Lights
Removal
Column Heavy Ends Column
Cativa
SCHEMATIC PROCESS FLOW DIAGRAM
Off-gas Recovery Area
Reactor
(Mixed acid
For disposal)
CO and
methanol
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Internal Infrastructure
Keys to Project Value
Build at scale
Locate near market
Locate close to petcoke feedstock
Integrate common infrastructure
Lever the strengths of both
parties
Value Levers: Project Integration
ASU AA Purification
Petcoke Gasification
External Infrastructure
2013 BP Chemicals Limited All rights reserved
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Acetic Acid is a petrochemical building block for products associated with a sophisticate growing modern economy
BP has developed world leading technology for the manufacture of acetic acid.
Feedstock choice is critical
Integration opportunities help to lever value
Thank You
Summary
2013 BP Chemicals Limited All rights reserved