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Laurent Samy
Recent Technology Developments to Support Petrochemicals Demand
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Be Close to Your Needs, Our Approach
Close to
your needs
Strong scientific
background
Complete portfolio:
processes & catalysts Design
efficiency
Operators
training
Start-up
assistance
Follow-up
Tech Services
Advanced
services
• APC
• Simulator
IPA - 14 June 2016
Your
Plant /
Project
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Basically all countries …
• Argentina
• Brazil
• Chili
• Mexico
• Uruguay
• Venezuela
Providing Technologies for Petrochemicals South & Latin America
IPA - 14 June 2016
… and all technologies
• AlphaButol co-monomer grade 1-butene
alpha olefin
• Selective hydrogenations (C3, C4, pygas)
• Etherifications
• Octenes via Dimersol-X dimerization
• Benzene saturation
• Prime-G+
• Reforming
• Isomerization
• …
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Recent Developments in Line with Market Evolution
• Alpha Olefins
• Renewables
Optimization of Existing Technologies
• Energy Efficiency and Water Footprint Reduction
Agenda
IPA - 14 June 2016
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Recent Developments in Line with Market Evolution
• Alpha Olefins
• Renewables
Optimization of Existing Technologies
• Energy Efficiency and Water Footprint Reduction
Agenda
IPA - 14 June 2016
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The Ethylene Plant Example Large Portfolio downstream Steam Cracking
MAPD selective
hydrogenation
C4 acetylenes
selective
hydrogenation
Purification
Multibed
Dimerization
AlphaButol
Trimerization
AlphaHexol
Butadiene
BD rich
selective
hydrogenation
Butadiene
Extraction
C4
etherification
Catacol
Skeletal
isomerization
Iso-5
C4/C5 olefins
hydrogenation
C5 etherification
Catacol
Pygas 1st Stage
Hydrogenation
(GHU-1)
Pygas 2nd Stage
Hydrogenation
(GHU-2)
BD lean selective
hydro
2-butene
maximization
Isobutene
Purif
Isopure
Oligomerization
Selectopol
Polynaphtha
PolyFuel
Olefins
hydrogenation
Aromatics recovery
Sulfolane
Morphylane
Dimerization
Dimersol-X
Hydration
Dehydrogenation
Super
fractionation
BD lean selective
hydro
1-butene
maximization
Ste
am
Cra
ck
er
Fu
rna
ce
s &
Dis
tilla
tio
n S
ec
tio
n
Removal of
arsenic &
mercury
RAM II
1-hexene
Propylene
Butadiene
1-butene
Isobutane
Isobutene
Octenes
N-butane
MEK
MTBE, ETBE
Solvents
TAME, TAEE
Benzene
Toluene
Mixed xylenes
to car
fuels pool Condensates
Ethylene
Benzene production
(HydroDeAlkylation)
Benzene
saturation
Cyclohexane Cyclohexane
C3/C4 total
hydrogenation
C5
C6+ C6-C8
C9+
2-butenes
rich cut
Advanced Pygas
Upgrading
APU
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Powerful tool to produce co-monomers
• High quality
• On-demand
• Efficient use of raw material
• Cost effective route
Good match especially with ethane based crackers
• Low cost ethylene, lack of C4’s
• Recent south and latin Amrica context
› Last 3 ethylene plants s/u are ethane based
› Brazil: Braskem UNIB-4, Duque de Caxias
› Venezuela: Polinter, El Tablazo
› Mexico: Braskem-Idesa Etileno XXI, Coatzacoalcos
Olefins: On-Purpose Processes
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Olefins: On-Purpose Processes Success of Selectivity On-purpose Mechanism
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Selective formation of the alpha-olefin
• Not a chain growth mechanism
• Highly selective towards desired oligomer
Carbon number Carbon number
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Polymerization Alpha Olefins Production
IPA - 14 June 2016
AlphaButol®
AlphaHexol™
Selective ethylene trimerization
Selective ethylene dimerization
Successful
Commercialization
>30 references
Recently Born Process
similar to AlphaButol®,
strongly backed up by
extensive industrial
experience in
homogeneous catalysis
1 commercial reference
Applications:
Co-monomers
HDPE &
LLDPE
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Adaptation through Technology Answer Ethane Based Crackers Specific Context
IPA - 14 June 2016
High purity co-monomers
Highly efficient ethylene use
CAPEX effective solution
Stereospecific chemistry made licenced
technology matching market demand
AlphaButol® AlphaHexolTM
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Recent Developments in Line with Market Evolution
• Alpha Olefins
• Renewables
Optimization of Existing Technologies
• Energy Efficiency and Water Footprint Reduction
Agenda
IPA - 14 June 2016
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Tomorrow’s feedstocks ?
• Oil and gas: for sure, as long as available
• Other sources: likely to grow
› Renewable oils and fats
› Lignocellulosic biomass
› …
Growing contribution of alternatives sources
• Uncertain timing
• Preparation/development on its way
Preparing Tomorrow’s Petrochemicals
IPA - 14 June 2016
Renewable
Oils & Fats
Lignocellulosic
Biomass
Oil
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Biosourced Materials Providing Environmental Performance
IPA - 14 June 2016
Vegan™
Gasel™/BioTfueL™ Project
Futurol™ Project
Atol™
BioTCat™ Project
BioButterfly Project
Renewable
Jet & Diesel
(HVO/HEFA)
High Quality
JET & DIESEL
2G ETHANOL
BIO-ETHYLENE
BIO-AROMATICS
BIO-BUTADIENE
GREEN
POLYMERS
GREEN
FUELS
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Alternatives & Renewables
IPA - 14 June 2016
Fuels
From Biomass,
Coal or Gas
Gasel®
Fischer-Tropsch + Hydrocracking
technology suite
High Quality 2nd generation
Bio-Naphtha & Bio-Diesel
& Bio-Jet
Gas
Bubbles
Slurry
Outlet
Offgas
Wax
Slurry
Return
Liquid
recirculation Dense phase
or slurry
Syngas inlet
1st Commercial reference:
Ajos Finland
Pilot Plant
From Biomass
Futurol™ Project Cellulosic Ethanol
Production Technology
And others…
Simple and integrated 4-step
process
1) Pretreatment
2) Biocatalysts production
3) Hydrolysis & Fermentation
4) Product recovery
Vegan™
Hydroprocessing of Oils & Fats
High Quality transportation
Bio-Diesel & Bio-Jet Fuels
1st Commercial reference:
HYDROTREATMENT
HYDROCRACKING
& ISOMERIZATION
OILS & FATS
JET & DIESEL
NAPHTHA
H2
PROPANE
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Alternatives & Renewables
IPA - 14 June 2016
Bio-based Petrochemicals
From Biomass
Bio-ethylene from ethanol:
Atol™
Bio-butadiene from biomass:
BioButterfly™ Project
BIOMASS BIOMASS TO
ALCOHOLS
CATALYTIC
REACTIONS
& SEPARATION BUTADIENE
Technology under development:
BIOMASS BIOMASS TO
ETHANOL
ETHANOL TO
ETHYLENE ETHYLENE
Technology:
Aromatics from biomass
Bio-TCatTM Project Technology under development:
NON-FOOD
BIOMASS
CATALYTIC
FAST
PYROLYSIS
BENZENE
TOLUENE
PARAXYLENE HYDROTREATMENT
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Renewable Fuels & Chemicals Futurol™ Technology
IPA - 14 June 2016
• Simplicity and Robustness
compact scheme
& few production steps :
- Single-train pretreatment,
- One-pot hydrolysis fermentation
• Integration and
Cost Competitiveness
in line with 1G bio-ethanol
production costs
- Energy and water management,
- On-site biocatalysts production and
propagation
• Biomass Flexibility
developed and tested on a
wide range of biomasses
- Suitable for worldwide deployment
- Possibility to take advantage of any
feedstock opportunities.
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Transesterification Hydrotreatment
Vegan™ Product: Premium Quality Biofuel
IPA - 14 June 2016
Biodiesel
(FAME1)
H2 CH3OH
Renewable
diesel (HVO2)
Renewable
Oils & Fats
High blending value, oxygen-free product
Higher energy density
Tunable cold flow properties
Production of Biojet blend stock
Improved ignition (higher cetane number)
Better blended product stability
Reduced waste & by-products production
Higher feedstock flexibility (UCO, FFA, …)
Advantages of Renewable Diesel (HVO)
1: Fatty Acid Methyl Ester 2: Hydrotreated Vegetable Oil
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Vegan™ Renewable Iso-paraffins Route
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Hydrogenation &
Decarboxylation
Oxygen removal,
olefin saturation
HDI
High Quality
Renewable
Diesel & Jet
Hydro-isomerization
(HDI) to improve
cold flow properties
Hydrocracking
if jet is desired
Pretreated
Renewable
Oils & Fats
HDT
1 2
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40
80
120
-50
0
50
Cold Flow Properties
Vegan Products High Blending Value Biofuels
IPA - 14 June 2016
0%
20%
40%
60%
80%
100%
Cetane Index Cetane Index
Diesel/Jet and Naphtha Yield Specific Gravity
0.7
0.8
0.9
1
Diesel Specification
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First Vegan™ Industrial Reference
Retrofit of two HDT Units into a Vegan™ Unit
200 Million Euros Overall Investment
Production of 500,000 t/y of Renewable Diesel
Fast-track project: Start-up in 2017 (basic design already
completed)
Vegan Insutrial Reference Total La Mède Biorefinery Project
IPA - 14 June 2016
Announced by TOTAL - April 2015
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Hydrotreating of renewable oils
• Long chain paraffinic materials
• Saturated, deoxygenated
Quality feedstock for steam cracking furnaces
Expected yields
comparison
Vegan 1st Step used for Petrochemicals Change Renewable Oils & Fats into Valuable Cracker Feed
IPA - 14 June 2016
Use Vegan™ Technology
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Major Actor for Petrochemical Intermediates
IPA - 14 June 2016
Refinery /
Petrochemicals
synergies
32 co-monomer
grade alpha olefins
references
Major
Actor
FCC alliance Axens – Technip
– IFPEn – Total
> 60 units
Aromatics
complexes
> 20 ParamaX
> 25 Eluxyl
Others Octenes via
Dimersol-X
C4 purifications
Vegan …
>60
etherefication
units
> 600 selective
hydrogenation
references
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Recent Developments in Line with Market Evolution
• Alpha Olefins
• Renewables
Optimization of Existing Technologies
• Energy Efficiency and Water Footprint Reduction
Agenda
IPA - 14 June 2016
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Basic Engineering is a Key Step of a Project
1- Technical
Consulting
2- Basic
Engineering
Project
schedule
3- Detailed
Engineering
4- Construction
Basic
Engineering
Construction
Licensor
Selection
Detailed
Engineering
Client project
launch
The licensor
is the unit’s
Architect
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Axens Innovative Approach
P
F
D
P
I
D
Preparation of
PID, Equipment
Preparation of
lines,
instruments
Basic
Engineering
CEED
Licensor
Selection
C
E
E
D
Work together to develop a
During an Early phase of the Basic Engineering Design
Using qualitative & quantitative analysis to evaluate
alternate schemes pros & cons
Selecting the most appropriate options taking into account:
Energy and/or Water constraints
CAPEX, OPEX, flexibility/operability
To ensure your project is built on solid process
foundation and to provide the best possible return
Custom & Efficient Early Design
IPA - 14 June 2016
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CEED : Collaborative Phase & Powerful Decision-Support Tool
Number of meetings/ conf. call
before H&MB / PFD finalization
A lot of exchanges with customer in a tight schedule...
… To propose various options evaluated using several criteria
selected by the customer A powerful decision-support tool
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100
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CAPEX ENERGY Utilities
Consumption
Options
A
C
B
Typical
With CEED Number of weeks before
H&MB / PFD finalization
100 Basis Index for Base Case (Option A)
After licensor
selection
D
Base
Case
WATER Consumption
100
CO2
Emissions
NPV (Net Present Value)
@10%, 15 years
Base
Base +3 weeks
Base
Base + 100% (x 2)
Low
Energy
Very Low
Energy
Low
Water
+ Dedicated
operability
report for
each option
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Conclusion
IPA - 14 June 2016
Axens at the forefront of Innovation with
Advanced Solutions & Technologies
• New processes
• Schemes improvement
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Thank you! And see you on Axens’ Blog
axens.net/blog
IPA - 14 June 2016