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contact us at: [email protected] www.fwc.com Chile Apoquindo 3846, Edif. Alsacia, Piso 7, Las Condes, Santiago T +56 2 379 7500 F +56 2 379 7690 China Suite 1-16, 4th Floor, POS Plaza, 1600 Century Avenue, Pudong, Shanghai T +86 21 5058 2626 F +86 21 5820 4567 France 92 Quai de Bercy, 75597 Paris Cedex 12 T +33 1 43 46 40 00 F +33 1 43 46 47 00 Italy Via Sebastiano Caboto 1, 20094 Corsico, Milan T +39 02 44861 F +39 02 4486 3131 Russia Office E-100, Park Place 113/1, Leninsky Prospekt, 117198 Moscow T +7 495 662 3617 F +7 495 662 3618 Singapore 991E Alexandra Road, Block 7 #01-25, Singapore 119973 T +65 6501 8888 F +65 6273 1015 South Africa 2nd Road, PO Box 76, Halfway House, Midrand 1685 T +27 11 690 0400 F +27 11 315 0243 Spain Edificio Foster Wheeler, Calle Gabriel Garcia Marquez, 2, 28230 Las Rozas, Madrid T +349 1 336 2500 F +349 1 336 2555 Switzerland Lohweg 6,CH-4054 Basel T +41 61 283 2200 F +41 61 283 2201 Thailand 217 Moo 12, Sukhapiban 8 Road, Tungsukhla, Sriracha, Cholburi 20230 T +66 38 352 200/6, 768 400/3 F +66 38 352 226/444 Turkey Kozyatagi-Sari Kanarya Sokak 22, Yolbulan Plaza, B-Blok, 34742 Kozyatagi, Istanbul T +90 216 445 1335 F +90 216 445 1336 UK Shinfield Park, Reading, Berkshire, RG2 9FW T +44 (0)118 913 1234 F +44 (0)118 913 2333 USA 585 Dairy Ashford, Houston, Texas 77079 T +1 713 929 5000 F +1 713 929 5170 ENGINEERING CENTERS TOMORROW’S SOLUTIONS FOR TODAY’S MARKETS Chemicals, Petrochemicals & Polymers [email protected] www.fwc.com

TOMORROW’S SOLUTIONS FOR TODAY’S MARKETS · a delayed coker, a gasification plant, ... our EPC project execution, ... expertise to develop the optimum construction strategy

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Page 1: TOMORROW’S SOLUTIONS FOR TODAY’S MARKETS · a delayed coker, a gasification plant, ... our EPC project execution, ... expertise to develop the optimum construction strategy

contact us at:[email protected] www.fwc.com

ChileApoquindo 3846, Edif. Alsacia, Piso 7, Las Condes,SantiagoT +56 2 379 7500 F +56 2 379 7690

ChinaSuite 1-16, 4th Floor, POS Plaza, 1600 Century Avenue,Pudong, ShanghaiT +86 21 5058 2626 F +86 21 5820 4567

France92 Quai de Bercy, 75597 Paris Cedex 12T +33 1 43 46 40 00 F +33 1 43 46 47 00

ItalyVia Sebastiano Caboto 1, 20094 Corsico, MilanT +39 02 44861 F +39 02 4486 3131

RussiaOffice E-100, Park Place 113/1, Leninsky Prospekt, 117198 MoscowT +7 495 662 3617 F +7 495 662 3618

Singapore991E Alexandra Road, Block 7 #01-25, Singapore 119973T +65 6501 8888 F +65 6273 1015

South Africa2nd Road, PO Box 76, Halfway House, Midrand 1685T +27 11 690 0400 F +27 11 315 0243

SpainEdificio Foster Wheeler, Calle Gabriel Garcia Marquez, 2, 28230 Las Rozas, MadridT +349 1 336 2500 F +349 1 336 2555

SwitzerlandLohweg 6,CH-4054 BaselT +41 61 283 2200 F +41 61 283 2201

Thailand 217 Moo 12, Sukhapiban 8 Road, Tungsukhla, Sriracha,Cholburi 20230T +66 38 352 200/6, 768 400/3 F +66 38 352 226/444

TurkeyKozyatagi-Sari Kanarya Sokak 22, Yolbulan Plaza, B-Blok,34742 Kozyatagi, IstanbulT +90 216 445 1335 F +90 216 445 1336

UKShinfield Park, Reading, Berkshire, RG2 9FWT +44 (0)118 913 1234 F +44 (0)118 913 2333

USA585 Dairy Ashford, Houston, Texas 77079T +1 713 929 5000 F +1 713 929 5170

ENGINEERING CENTERS

TOMORROW’SSOLUTIONS FOR

TODAY’S MARKETSChemicals, Petrochemicals & [email protected] www.fwc.com

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Foster Wheeler has over 70 years’experience in the chemicals andpetrochemicals industry.

We’ve completed thousands of projects;grassroots facilities, expansions andupgrades. Our experience and capabilitiesencompass plants that produce feedstocks,intermediate products and finishedproducts, including:

• olefins and derivatives• aromatics• fiber intermediates such as PTA • polycarbonates• a wide range of polymers• fertilizers• fine and specialty chemicals• inorganic chemicals• synthesis gas

Our major operating centers, regionaloffices, local and strategic partners ensurethat we are ideally placed to provideexpert help in the key locations for the chemicals industry.

Our teams have in-depth experience instate-of-the-art technologies and canprovide a completely objective evaluationof the full range of options.

We can bring expertise to the entire valuechain of the oil and gas industry, from thewellhead to LNG and gas-to-liquids, torefining and petrochemicals, and throughto fine chemicals and pharmaceuticals.

DELIVERINGEXCELLENCEFROM THE PLANNING STAGE TO PROJECTIMPLEMENTATION, WE ADD VALUE

2

OUR TECHNICAL EXPERTISE AND EXTENSIVEINTERNATIONAL EXPERIENCE MAKE US ONE OF THEWORLD’S LEADING CHEMICALS, PETROCHEMICALSAND POLYMERS CONTRACTORS.

1

Front cover image courtesy of Shell International Limited.

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VALUE-ADDED CONSULTANCYWe have completed many investment studies andtechnology evaluations for petrochemical revamps,upgrades, grassroots plants and petrochemical/refinery integration. Our clients include operatingcompanies, government bodies and institutions.

We offer a full planning service from feasibilitystudies to the provision of an overall ‘master’ plan.

We have a proven capability for undertaking studiesto identify marketing opportunities and provide theoptimum processing facilities for our clients.

To develop the optimum solution, we combineobjective technology selection, linear programing or simulation modeling of petrochemicalsconfiguration options, cost estimates based on real, extensive in-house data and in-depth local knowledge.

These models are particularly useful when used toupdate scheduling and planning capability forrefinery integration.

We invest time and effort in capturing lessons learnt,sharing best practice, and applying proven valueimprovement practices to deliver value for money to our clients.

3

We offer a completerange of services to meetour clients’ needs:

• Technical consultancy• Market studies• Feasibility studies• Master planning• Site selection• Project development• Concept design• Technology packages• Front-end design• Project management• Environmental services• Detailed engineering • Procurement • Construction &

construction management• Commissioning & start-up• Validation• Plant operations &

maintenance• Training• Turnarounds• Site remediation

OUR EXPERIENCED CONSULTANTS DELIVERTECHNICAL AND ECONOMIC PLANS FOR COST-EFFECTIVE CHEMICALS INVESTMENT.

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INSIGHT &INNOVATION

“ ”Project HighlightABU DHABI OIL REFINING (TAKREER)UAEDetailed feasibility study for production of paraxylene, benzene and gasoline at the Abu Dhabiand Ruwais refineries.

“WE ARE PLEASED THAT FOSTER WHEELER IS ASSISTING TAKREER IN MAPPING OUT THEFUTURE DIRECTION OF ITS FACILITIES. THE PRODUCTION OF PARAXYLENE ANDBENZENE FROM A NEW AROMATICS COMPLEX WILL FURTHER ENHANCE TAKREER’SCOMPETITIVE POSITION IN THE MARKET PLACE.”Mansoor Al-MehairbiBusiness Development Manager, TAKREER

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FRONT-END EXCELLENCECritical to success is defining theright project and then giving it theright start. We provide objectiveassistance with technology evaluationand selection, coupled with high-quality conceptual, feasibility andfront-end packages.

Linking our process expertise and ourproject execution/estimating skillsand IT tools, we apply valueimprovement practices during theearly phases of a project, to deliverthe greatest benefit.

We have executed more than 200major FEEDs in the last 15 years.

ADDINGFRONT-END

VALUE

“ ”

Project HighlightCJSC NIZHNEKAMSKTatarstanFEED for a new complex consisting of a refineryaimed at processing seven million tpa of crude oil, a deep conversion plant, an aromatics-basedpetrochemical plant, polypropylene facility, a delayed coker, a gasification plant, plusassociated power generation facilities.

“WE ARE PLEASED WITH FOSTER WHEELER’SPROFESSIONALISM, RESPONSIVENESS TOOUR NEEDS AND ITS CAPABILITY TOMOBILIZE HIGHLY-QUALIFIED RESOURCESFROM ITS EUROPEAN OFFICES AS WELL ASFROM ITS MOSCOW OPERATIONS.”Khamza A BagmanovGeneral Director, CJSC Nizhnekamsk Refinery

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EPC EXPERTISEOur network of execution centers provides our clients with local access to our global resources.

Excellence underpins our project management trackrecord and contributes significantly to our high level ofrepeat business. We have a reputation for providingworld-class project management, as an integral part ofour EPC project execution, or working with our clients astheir project management consultant.

We deliver a high quality product, with engineeringexperts who design with a focus on safety, cost,constructability and operability. Our engineers follow thejob through to site and take an active role in constructionand commissioning.

We have the expertise, negotiating power and flexibility to match the supply of materials and services to our clients’ cost, schedule, quality, local content and exportcredit needs. We have successfully developed and workedwith equipment vendors in China, India and other lower-cost fabrication centers.

With significant modularization experience, we have theexpertise to develop the optimum construction strategy.

WORLD-CLASS HSEWe are proud of our reputation for world-class HSEperformance and are the only E&C contractor to date to have won the Singapore Ministry of Manpower’sOccupational Health and Safety Excellence Award foroutstanding project HSE performance.

Our construction management personnel are highlyexperienced and culturally-aware professionals whoexpect the same world-class HSE standards on theirconstruction sites, wherever in the world we work.

AS AN EPC CONTRACTOR OR PROJECT MANAGEMENTCONSULTANT, WE HAVE EXECUTED PROJECTS WITH A TOTAL INSTALLED COST FAR EXCEEDING $80 BILLION.

DELIVERINGEPC

SUCCESS

Project HighlightEQUATE

KuwaitLump-sum turnkey project, completed within an

ambitious 24-month schedule, for a plant producingpolyester-grade ethylene glycol. Foster Wheeler is now

designing and constructing a second world-scaleethylene glycol unit at this site.

WE’VE WORKED HARD TOESTABLISH A REPUTATIONFOR DELIVERING HIGHQUALITY FACILITIES WHICHSTART UP SMOOTHLY ANDPERFORM RELIABLY.

Image: Courtesy of Shell Eastern Petroleum (Pte) Ltd.

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Biomass

Chemicals

Biofuels

Crude

Fuels

Biomass CO2 capture

Chemicals

Biomass

Coal

Gas CondensatePowerBiofuels

LightOlefins

OlefinsPlant

Feedstock

C4Chemistry

PyrolysisGasoline

Fuel ValueStreams

Aromatics

GasificationSyngas

Production

Ref

inin

g

Pet

roch

emic

als

We have a strong track record ofachievement and demonstrable expertise. We are proud to be involved in some of the world’s largest refinery/ petrochemicals projects:

• ExxonMobil’s Singapore Parallel Train

• Shell Eastern Petroleum, Singapore

• PETRORabigh, Saudi Arabia

• Nizhnekamsk, Tatarstan, for Tatneft

• IOCL, Paradip, India

We add value, from concept to completion.Dealing with the newest technologies, such ashigh olefins-producing FCCs and gasification,we are a leader in the industry with our abilityto optimize investment and then implementprojects successfully.

PETROCHEMICALS& THE REFINERYINTERFACE

“ ”“WE SELECTED FOSTER WHEELER AFTER A RIGOROUS REVIEW PROCESS OF COMPETITIVE BIDSBECAUSE OF THEIR IN-DEPTH PETROCHEMICAL EXPERIENCE AND THE QUALITY OF THEIR PASTWORK FOR SAUDI ARAMCO, PARTICULARLY IN PRODUCING HIGH QUALITY FEEDS, ON TIME, AS THEY DID FOR OUR HARADH AND QATIF PROJECTS.”

Isam A Al-BayatVice President, New Business Development Saudi Arabian Oil Company

Project HighlightPETRORABIGH REFINING/PETROCHEMICAL COMPLEX(SAUDI ARAMCO/SUMITOMO CHEMICAL CO.) Saudi ArabiaWe undertook the feasibility study and then were awarded the overall FEED and project management for thisprestigious project, and EPC of the utilities and offsites. This is one of the largest integrated complexes ever tobe built at one time.

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TURNAROUNDSFoster Wheeler has an excellent track record for delivering successfulturnarounds. We are able to managean entire operation or work as part ofan integrated team or alliance. Ouraim is always to deliver the shortestpossible safe turnaround.

Our extensive experience in planningand implementing these difficultoperations allows our clients to meetthe toughest schedules and budgetswhile never compromising on safety.

Our ability to react quickly andmanage emergent work during theturnaround itself has time and time again enabled challenging schedules to be met.

A RESPONSIVE SERVICEWe have built strong workingrelationships with many of our clientsthrough ‘term services’ agreements,providing local or on-site flexible andresponsive services for a completerange of projects, backed up by theexpert resources in our majorengineering centers.

For example, we have an allianceagreement with SABIC Europe for itsolefins and aromatics businesses(formerly Huntsman assets) onTeesside, UK. We provide detailedengineering, procurement andconstruction management services.

In China we have a rapidly expandingclient base for term services. Suchservices also form an important partof our activities throughout Asia and Europe.

“The team has a veryproactive approach andthe team members arenot afraid to ‘roll up’their sleeves. There aretoo many names tomention individually, but the whole Allianceteam has made anoutstanding contributionto achieving our business objectives.”

Colin StewartBusiness Projects & Overhauls ManagerHuntsman Petrochemicals (UK) Limited

MAXIMIZINGEXISTING ASSETS

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large huntsman pic

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A PROVEN TRACK RECORDOLEFINS & DERIVATIVESPETRORABIGH (SAUDI ARAMCO/SUMITOMO CHEMICAL CO.)Saudi ArabiaWe have been awarded the overall FEED and projectmanagement, and EPC of the utilities and offsites for this prestigious project at Rabigh, one of the largestintegrated complexes ever to be built at one time.

CJSC NIZHNEKAMSKTatarstanFeasibility studies and FEED for a new complex consistingof a refinery aimed at processing 7 Mtpa of crude oil, a deep conversion plant, an aromatics-basedpetrochemical plant, polypropylene facility, a delayedcoker, a gasification plant, plus associated powergeneration facilities.

EASTERN PETROCHEMICALS COMPANY(SHARQ)Saudi ArabiaEPC contractor for the utilities and offsites for a major expansion at SHARQ’s existing chemicals complexat Al-Jubail, and FEED and program managementcontractor for the entire expansion.

SABIC (YANSAB)Saudi ArabiaFEED and program management contractor for newgrassroots petrochemicals complex at Yanbu with anannual production capacity of 3.6 million metric tonnes.This is one of the largest petrochemical complexes to bebuilt in the Middle East and will include a 1.3 Mtpaethylene plant.

PROJECT MANAGEMENT & DEVELOPMENTSaudi Arabia(now known as Saudi Kayan)Technical consultancy for development of a majorpetrochemical complex, including an ethane/butanecracker producing ethylene, propylene and benzenefeedstocks for downstream petrochemical units within the same complex.

SAHARA PETROCHEMICAL/BASELL POLYOLEFINSSaudi ArabiaProject management consultancy for a new460,000 tpa propane dehydrogenation unit toconvert propane to propylene, a 450,000 tpapolypropylene production unit, and all associatedutilities and offsite facilities.

KAZMUNAIGASKazakhstanDetailed feasibility study for a new petrochemicalcomplex and related facilities to be built in theRepublic of Kazakhstan.

CSPCChinaPart of the BSF consortium, which was projectmanagement contractor for the definition andimplementation phases of this $4.3 billionpetrochemicals complex. This greenfield projectinvolved an 800,000 tpa ethylene unit (lowerolefins plant), together with other downstreamprocess units (LDPE, LLDPE/HDPE, EO/EG,polypropylene, styrene monomer, butadiene,propylene oxide, polyols and propylene glycol),and associated offsites and infrastructure.

INDIAN OIL CORPORATIONIndiaFEED, preparation of cost estimates and overallproject strategy, and supervision of early works onsite up to financial investment decision for a world-scale facility, comprising a new export refinery andpetrochemicals complex, to be built in OrissaState. Project includes a fluidized catalytic crackingunit, an aromatics complex and a polypropyleneunit and will ultimately produce 700,000 tpa ofpolypropylene, 1.2 Mtpa of paraxylene, 600,000tpa of styrene monomer, along with 10.5 Mtpa ofrefined petroleum products.

EXXONMOBIL CHEMICALSingaporeWe are working on the early phase of the FEED for certain downstream units and associated plantinfrastructure for a potential new world-scalesteam-cracking complex that would be located at ExxonMobil’s existing Singapore refining andchemical plant site.

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A PROVEN TRACK RECORD

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AROMATICS & FIBER INTERMEDIATESBPBelgiumFront-end loading and EPC for grassroots paraxyleneplant. Award-winning safety record, and plant meetssome of the world’s most stringent community noise restrictions.

SINGAPORE AROMATICS COMPANYSingaporeEPC for aromatics complex producing 350,000 tpa of paraxylene, 95,000 tpa of benzene and associated by-products. Design, which was based on modularconstruction, fabrication, construction and pre-commissioning were completed in 32 months.

EXXON CHEMICALRotterdam EPC for expansion and modification of aromatics plant, including revamp of existing isomerization unitand installation of new twin train paraxylene recoveryunit. Completed ahead of schedule, setting a newindustry benchmark.

ESSOThailandEPC of process units and offsites, including existingprocess unit revamp and marine facilities, for recoveryof high quality paraxylene from reformate. Completedahead of schedule and with a world-class safety record.

ATCThailandProject management of EPC and commissioning phasesfor new aromatics complex and offsite interconnectingpipeline, producing 565,000 tpa of paraxylene,301,000 tpa of benzene and 60,000 tpa of toluene.

INDORAMAThailandEPCm for this grassroots PTA plant, designed to produce640,000 tpa. Production started only 27 months aftercommencement of basic engineering.

INVISTA/ORIENTAL PETROCHEMICALSChinaBasic engineering design for new 600,000 tpa PTAplant, procurement services and ITB preparation for EPC contract, and EPC contractor support. We are apreferred contractor for INVISTA’s PTA technology.

THAI PARAXYLENE COThailandFEED and PMC for original paraxylene plant, and FEEDand PMC for EPC phase of a later revamp, increasingoutput from 288,000 to 348,000 tpa.

ABU DHABI OIL REFINING (TAKREER)UAEDetailed feasibility study for production of paraxylene,benzene and gasoline at the Abu Dhabi and Ruwais refineries.

FINE & SPECIALTY CHEMICALSINVISTA FOR SK CORPORATIONSouth KoreaBasic engineering design and technical services for a 40,000 tpa butanediol plant.

GULF FARABISaudi ArabiaProject management and project specification for120,000 tpa n-Paraffin plant and 70,000 tpa linearalkyl benzene plant.

LUCITE INTERNATIONALSingaporeFEED/EPC for this new 120,000 tpa plant producingmethyl methacrylate. This is the first commercial plant using Lucite International’s state-of-the-art Alpha technology.

JANASaudi ArabiaProject engineering services contractor for EPC phase for facility to produce epichlorohydrin, caustic soda and calcium chloride.

PTT PHENOLThailandFEED and project management for Thailand’s firstphenol plant. Now awarded FEED for Thailand’s first Bisphenol-A plant.

DEGUSSAChinaEPC for new 3,500 tpa organic peroxide productionfacility, Jade II, including production building,warehouse, low-temp warehouses, tank farm, substation and piperack.

SASOL/MITSUBISHI South AfricaThis acrylic acid and acrylates complex was completedon time, under budget, with an excellent safety record, to a high quality level and beating the worldconstruction norm for these plants by three months.

OSOS PETROCHEMICALSSaudi ArabiaFEED and project management consultancy services fornew petrochemicals complex to produce 60,000 tpa ofpolybutylene terephthalate, including basic design forutilities and offsites, cost estimate, evaluation of EPCbids and assistance with EPC award.

INEOS SILICASChinaTwelve-week feasibility study for silica gels project, site overview and +/- 25% cost estimate.

CHROME INTERNATIONAL South AfricaDesigned and built a new world-scale facility, producingsodium dichromate and chromic acid. Met stringentcontainment requirements to capture Chromium IV, andbeat an ambitious schedule by one month with morethan 10% savings achieved against cost budgets.

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POLYMERS & POLYCARBONATESBAYERThailandEPCm for a new 50,000 tpa polycarbonate facility, PC1, including allsite infrastructure, followed by repeat award for an additional facility,PC2, twice the size of PC1. Start-up duration to achieving productionwas a Bayer record. Ongoing support also provided under a termservices contract.

EQUATEKuwaitLump-sum turnkey project, completed within an ambitious 24-monthschedule, for a plant producing polyester-grade ethylene glycol. Foster Wheeler is now designing and constructing a second world-scaleethylene glycol unit at this site.

SHELL EASTERN PETROLEUMSingaporeBasic design and engineering package, and EPCm for a world-scaleethylene oxide/mono-ethylene glycol plant and significant relatedrefinery modifications, part of a project known as the Shell EasternPetrochemicals Complex, which plans to capture the benefits of oil-chemicals integration.

BOROUGEUAEProject management contractor for expansion of existing facility, plusFEED for utilities and offsites. Tripling ethylene production, doublingpolyethylene product and adding polypropylene units.

CHEMOPETROLCzech RepublicEPC, start-up activities and initial plant operation of 250,000 tpa newpolypropylene plant using Ineos’ (BP Amoco heritage) licensedpolymerization technology. Very tight 27-month schedule to start-upachieved with outstanding safety performance.

PETRONASMalaysiaEPC of centralized utility facilities at Kertih and Gebeng and additionalLDPE project with steam generator, co-generation units, demineralizedwater plant, cooling water, effluent treatment plant, air separation units,auxiliary boilers and metering.

A PROVEN TRACK RECORD

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