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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