Detlef Kratz, BASF SE, Corporate Technology and Operational Excellence

March 9th 2015, Ludwigshafen

Putting Energy into Chemistry and Making Chemistry from Energy

Energy efficient Processes in Practice -

Challenges of today and tomorrow

High complexity due to diverse business, technology and site structure

BASF Site and technology portfolio Constant change over 150 Years through acquisitions and growth

Operations Footprint

~ 350 Sites

~ 1200 Plants

~ 500 Technologies

~ 70 Bn € Assets

~ 30.000 People

Raw Material and Energy Footprint

~ 44 Mio tons of Raw Material

~ 59 Mio MWh

… to make

~ 37 Mio tons of Products

> 10.000 Products

~ 17 Mio tons CO2

~ 0.023 Mio t emissions into waste water

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3

Operational Excellence Continuously improving asset performance and production costs

Asset Performance

Improved reliability

Optimized maintenance

Increased catalyst performance

More capacity

Reduced raw materials and utilities

Avoided waste and CO2 emission

…

Energy

Savings

Asset

perf

orm

an

ce

Original design or

current status

Reality without

Operational Excellence

Reality with

Operational Excellence

Time

“LEAN is...” Off gas scrubber Optimization

Current situation

Off-gas containing traces of acids

is treated in a caustic scrubber

Scrubber operated at pH ~ 12

OpEx solution

Reduce excess caustic consumption

by stepwise adaption of the pH value:

set point to lower values (pH ~ 10.5)

Current situation

Distillation towers running with fixed reflux

Plant trials with reduced reflux flows

without negative impact

OpEx solution

Install reflux ratio control instead

of flow control

Distillation tower Optimization

Current situation

Process: MeOH used in excess and

recycled via distillation

Fresh MeOH distilled prior to usage

OpEx solution

Energy saving via bypassing of MeOH

distillation tower as specifications fulfilled

Routing Optimization Batch Optimization

Current situation

Blending performed in adjustment tank

OpEx solution

With additional, inexpensive static

mixer, availability of tank is increased

leading to a higher production

Process Overview

Adjustment tank as mixing vessel

→ static mixer

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Technical Process Optimization Big value for small money!

Operational Excellence Database Collect ideas, identify measures, share best practices and capture value

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# measures

Continuous effort of operations and R&D

community

To date over 5.000 measures identified

High implementation rate

Pay-back significantly under one year

Driven by innovation and creativity

R&D supports process optimization

Benefits

Expenses

2013 to 2017

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CO2

CO2

20

13

2

01

4

-50 kt / year -230 kt / year -50 kt / year

-120 kt / year -380 kt / year -90 kt / year

Electricity/Fuel Raw Materials Steam

-330 kt / year

-590 kt / year

Total Savings

Contribution to sustainability Energy and raw material savings significantly contribute to a reduction of CO2 emissions

Total CO2 reduction grows with new and sustainable Operational Excellence measures!

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BASF’s chemistry in a nutshell Making chemistry from energy and natural resources

Sum formula of all BASF sales products

(C H3.2O0.3N0.2 ... )n

Coal

Gas

Oil

Plants

O2

N2

CO2

Steam

Electricity

H2O

Plant Oil

Crude Oil

Natural Gas

Coal

Corn

Nutrition

Energy /

Mobility

Nutrition

Cracking

Syngas

or

Acetylene

Starch

Hydrolysis

(Petro-)

Chemical

Verbund

Fermen-

tation

Oleo-

chemistry Oleochemicals

Ethanol

Alanine

…

Enzymes

Butane Diol

Acrylic Acid

Amines

...

Fipronil

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Verbund Types based on different feedstock BASF uses primary energies to produce key intermediates

Ethylene

Propylene

Benzene

...

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Chemistry is energy and energy is chemistry Raw materials contain value as carbon, as energy and from their functionality

600

25 Coal (China West)

Ethanol

Naphtha

Glucose

Methanol

Propane

Natural Gas

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1

carbon world

[€/mmBTU] [€/mt]

and energy world

Simplified energy diagram Heatmap of key raw materials

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Renewables

CO2

H2O

(C H3.2O0.3)n

Chemistry is energy and energy is chemistry Naphtha cracking as conventional source for olefins

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(CH2)n → C2H4 + C3H6 + ...

Olefins

Chemistry is energy and energy is chemistry Natural gas for olefins production

12

CO

CH4 + ½ O2 → CO + 2 H2

CO + 2 H2 → CH3OH

plus gasoline as

by-product

Methan to Methanol to Propylene (MMTP)

A Propylene route with detours

Large production of steam

Significant Gasoline production

3 CH3OH → C3H6 + 3 H2O H2O Olefins

plus gasoline as

by-product

3 CH3OH → C3H6 + 3 H2O

Chemistry is energy and energy is chemistry Using coal as chemical feedstock

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CO

2 (CH)n + O2 → 2 CO + H2 Coal to Methanol to Propylene (CMTP)

A Propylene route with detours

Large production of CO2

Significant Gasoline production

2 CO + H2 + H2O → CO + 2 H2 + CO2

CO2

H2O CO + 2 H2 → CH3OH Olefins

Challenge 1: Direct coupling of C-C bonds Selective C-C coupling avoiding CO and MeOH steps

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3 CH4 → C3H6 + 3 H2 No or low conversion

Target other products such as

benzene

Energy/Chemical interface

with H2 consumer and…

… potentially fuels as side product

Olefins

Benzene

Challenge 2: Activation of aliphatic CH-bonds Selective functionalization of C-H to MeOH

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CH4 + ½ O2 → CH3OH

3 CH3OH → C3H6 + 3 H2O

H2O

Heterogeneous or Bio-catalysis ?

Functionalization of Alkanes

- Cyclohexanol

- Butanol ?

- Ethanol ?

Olefins

Challenge 3: Direct transformation of coal to olefins Avoid oxidative activation of coal to save energy and avoid CO2 emission

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Hydrogen 3 (CH)n + 2 H2 → C3H6

1.5 (CH)n + 1.5 CH4 → C3H6

But where does the H2 come from?

Hydrocarbon energy transformation

Rethink sources of Hydrogen

Olefins

Challenge 4: Carbon-free production of hydrogen Developing a holistically sustainable approach

H2

CO2

Efficiency 70-90 %

Oil

Gas

Coal

(Renewables)

Partial Oxidation

Reforming

O2

Efficiency 45-60 %

CO2 / H2O

Power Plant

O2

Electricity

O2

Efficiency 60-70 %

H2O

Electrolysis

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Challenge 5: Renewables for functionalized products Intelligent chemistry from renewables

H2O

Renewables

C6H12O6 → 2 C2H5OH + 2 CO2

C6H12O6 + 2 CO2→ 2 C4H6O4

Succinic Acid

Ethanol

CO2 CO2

Carbon Footprint Olefins Full Cost Olefins

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Putting Energy into making Olefins Sustainability: Environmental and Cost Aspects

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1

Propane

Naphtha

Coal (China West)

Natural Gas

Glucose 3

10

[€/mmBTU] Specific CO2 Emission

Raw Materials

Capital Cost

Energy

Cost of Energy

C-C Coupling

C-H Functionalization

„Direct Coal“ processes

Carbon-free Hydrogen

Renewables for functionalized

Products

Energy/Chemical and Chemical/Energy

Interface

Energy efficient Processes - Challenges of today and tomorrow Putting Energy into Chemistry and Making Chemistry from Energy

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Succinic acid (Succinity)

Methane to benzene

Methane pyrolysis

FCC Catalysts ?

150 years

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