Mr. Jon Horler Acetyls Project & Engineering Manager BP
A Chartered Chemical Engineer, Mr. Jon Horler has worked for BP for 25 years and leads a team responsible for the delivery of technology and engineering in support of BP’s proprietary package for the manufacture of Acetic Acid. Part of his role is also to provide project management during concept selection and early stage development for licensing opportunities worldwide. Mr. Jon has previously worked on major projects in the UK, China, Taiwan, Malaysia, Korea and India.
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
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
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
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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 Cash cost = variable + fixed
Capital-related costs=depreciation + return on investment
•
120
Production cost [indexed to ethylene process total cost = 100]
CATIVA® gives advantages across all key project criteria: Capital - simplification of flowsheet results in lower project costs for new build plants
Time
100
•
Feedstock changes
80
• Cash Cost / Reliability - less equipment items to maintain mean lower annual maintenance spends and less downtime
Process changes
60
40
•
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
20
0
Ethylene
Naphtha
Hydrocarbon oxidations
Rhodium
Rhodium / lithium
Variable Cost - patented catalyst technology and subsequent reduced energy requirements result in lower operating costs
Iridium
Methanol carbonylation Cost estimates are based on generic models © 2013 BP Chemicals Ltd All rights reserved
Methanol Carbonylation: A C1 route to Acetic Acid CO must be generated locally Natural Gas
Purify CO
Coal
Compress CO
Pure CO
Pet Coke Naphtha Light HC’s
Syngas (CO + H2)
Acetic Acid (CH3COOH)
Heavy HC’s Biomass ……….
Methanol
Distribution
Methanol (CH3OH)
MeOH purchased as a globally traded commodity
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Relative Energy Cost
Feedstock Selection In India
• For a methanol carbonylation production, feedstock access for competitive CO production cost is key to the Acetic Acid value chain
Feedstock Options • 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 © 2013 BP Chemicals Ltd All rights reserved
BP Acetyls – Global Experience
Hull, UK Europe Commercial Office and Production
Nanjing, China
AA and Anhydrides
Byaco: AA , 50%
Naperville/Cantera
Chongqing, China
Commercial Office USA
Yaraco: AA &
Ulsan, South Korea SSBP: AA , 51%
Esters , 51%
Shanghai
Texas City
Head office
AA
Taiwan FBPC: AA, 50%
Kuala Lumpur Commercial office, Rest of Asia
Kertih, Malaysia BPPA: AA, 70%
Acetyls sites
Commercial/Sales offices % BP share of JVs
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CATIVA® Process Flow Diagram SCHEMATIC PROCESS FLOW DIAGRAM
Cativa®
Vent Gases To Flare
Off-gas Recovery Area
Lights Reactor
Removal Column
Heavy Ends Column
CO and methanol
Acetic Acid Product
(Mixed acid For disposal)
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Value Levers: Project Integration Internal Infrastructure Keys to Project Value
Petcoke ASU
• Build at scale
Gasification Purification
• Locate near market
AA
• Locate close to petcoke feedstock
• Integrate common infrastructure • Lever the strengths of both parties
External Infrastructure © 2013 BP Chemicals Limited All rights reserved
Summary
• 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
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