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A World of Solutions Innovative Double Reslurry Technology for Paraxylene Production 4th International Conference - Indian Polyester Mumbai, India
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Page 1: Innovative Double Reslurry Technology for Paraxylene ... · A World of Solutions Innovative Double Reslurry Technology for Paraxylene Production 4th International Conference - Indian

A World of Solutions

Innovative Double Reslurry Technology for Paraxylene Production

4th International Conference - Indian Polyester

Mumbai, India

Page 2: Innovative Double Reslurry Technology for Paraxylene ... · A World of Solutions Innovative Double Reslurry Technology for Paraxylene Production 4th International Conference - Indian

A World of Solutions

1

Safe Harbor Statement

This presentation contains forward-looking statements regarding CB&I and represents

our expectations and beliefs concerning future events. These forward-looking

statements are intended to be covered by the safe harbor for forward-looking

statements provided by the Private Securities Litigation Reform Act of 1995. Forward-

looking statements involve known and unknown risks and uncertainties. When

considering any statements that are predictive in nature, depend upon or refer to future

events or conditions, or use or contain words, terms, phrases, or expressions such as

“achieve”, “forecast”, “plan”, “propose”, “strategy”, “envision”, “hope”, “will”, “continue”,

“potential”, “expect”, “believe”, “anticipate”, “project”, “estimate”, “predict”, “intend”,

“should”, “could”, “may”, “might”, or similar forward-looking statements, we refer you to

the cautionary statements concerning risk factors and “Forward-Looking Statements”

described under “Risk Factors” in Item 1A of our Annual Report filed on Form 10-K filed

with the SEC for the year ended December 31, 2014, and any updates to those risk

factors or “Forward-Looking Statements” included in our subsequent Quarterly Reports

on Form 10-Q filed with the SEC, which cautionary statements are incorporated herein

by reference.

Page 3: Innovative Double Reslurry Technology for Paraxylene ... · A World of Solutions Innovative Double Reslurry Technology for Paraxylene Production 4th International Conference - Indian

A World of Solutions

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Double Reslurry Crystallization is the

CLEAR choice

Continuously improved for over 45 years

Lowest capex, opex and environmental emissions

Energy efficient

Ability to debottleneck or expand

Reliable

Page 4: Innovative Double Reslurry Technology for Paraxylene ... · A World of Solutions Innovative Double Reslurry Technology for Paraxylene Production 4th International Conference - Indian

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Paraxylene is a valuable aromatic isomer

Paraxylene (pX) is used in the polyester chain

pX is raw material to produce terephthalic acid (TPA), purified terephthalic acid (PTA) and dimethyl terephthalate (DMT)

TPA, PTA and DMT are used in manufacture of polyethylene terephthalate (PET) saturated polyester resins

Uses of polyesters include:

Bottles for liquids including water and carbonated beverages

Fiber used in fabrics for clothing and home furnishings

Industrial fibers – ropes and geotextiles

Films such as shrink wrap or boil-in bag pouches

Polyester demand is forecast to grow at 2-3 times the rate of other fibers

Paraxylene – Sources and Uses

Page 5: Innovative Double Reslurry Technology for Paraxylene ... · A World of Solutions Innovative Double Reslurry Technology for Paraxylene Production 4th International Conference - Indian

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Isomerization Xylene recovery

column

Double Reslurry

Crystallization

Hydrogen Feed mixed xylenes/heavy reformate Light

aromatics

pX

pX lean recycle

pX Recovery Process

Heavy aromatics

Page 6: Innovative Double Reslurry Technology for Paraxylene ... · A World of Solutions Innovative Double Reslurry Technology for Paraxylene Production 4th International Conference - Indian

A World of SolutionsTM 5 CB&I Technology Engineering Solutions------Delivering Results

BP Double Reslurry Crystallization

Crystallization Reslurry

Centrifuge Centrifuge

pX Product Lean Xylenes To

Isomerization

Xylenes from

Xylenes Recovery

Column

Reslurry

Centrifuge

Page 7: Innovative Double Reslurry Technology for Paraxylene ... · A World of Solutions Innovative Double Reslurry Technology for Paraxylene Production 4th International Conference - Indian

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Plant Location Capacity, kta

GS Caltex, Korea World Scale

Reliance Industries Limited, India 1,800

Crystallization Experience Base

BP Plant Location Capacity, kta

Geel, Belgium 675

Texas City, USA #3 390

Decatur, USA #2* 720

Texas City, USA #2 530

Decatur, USA #1* 380

Texas City, USA #1 350

Total 3,045

CB&I licensees:

50 years of continuous

improvement

*owned by Indorama as of May 2016

Page 8: Innovative Double Reslurry Technology for Paraxylene ... · A World of Solutions Innovative Double Reslurry Technology for Paraxylene Production 4th International Conference - Indian

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2000 2005 2010 2015 2020

$/m

etr

ic t

on

ne

of

pX

The Process Is Continuously Improving

Catalyst

efficiency

improvement

Crystallization

energy savings

Fractionation

Energy savings

Future

developments

Page 9: Innovative Double Reslurry Technology for Paraxylene ... · A World of Solutions Innovative Double Reslurry Technology for Paraxylene Production 4th International Conference - Indian

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2nd Catalyst Improvement - High Selectivity De-Ethylation (HSDE) Catalyst

oX and mX pX , ethylbenzene + H2 benzene + ethane

Non-noble metal

catalyst

Low xylene loss per pass

High benzene purity - only

requires fractionation

Close approach to

xylene equilibrium

for maximum pX

concentration

Readily recovers from

sulfur and other poisons

In situ regeneration

with N2 Over 10 year catalyst life

Result is lower capex and

opex

Page 10: Innovative Double Reslurry Technology for Paraxylene ... · A World of Solutions Innovative Double Reslurry Technology for Paraxylene Production 4th International Conference - Indian

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Double Reslurry Crystallization is the

CLEAR choice

Continuously improved for over 45 years

Lowest capex, opex and environmental emissions

Energy efficient

Ability to debottleneck or expand

Reliable

Page 11: Innovative Double Reslurry Technology for Paraxylene ... · A World of Solutions Innovative Double Reslurry Technology for Paraxylene Production 4th International Conference - Indian

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Operating cost is lower

Energy savings result in NPV benefit of $200-300 million (1 million mta pX)

Increased reliability results in additional $40-75 million NPV benefit

Lower Capex

Benefit of $25-75 million on a US Gulf Coast basis

Flexibility of process

Ability to process a wide range of feedstocks that is unmatched by other methods

Ability to expand at low cost

Option to utilize to debottleneck existing selective adsorption plant if feedstock has high paraxylene concentration

Double Reslurry Crystallization – The Best Method to Recover Paraxylene

Page 12: Innovative Double Reslurry Technology for Paraxylene ... · A World of Solutions Innovative Double Reslurry Technology for Paraxylene Production 4th International Conference - Indian

A World of SolutionsTM 11 CB&I Technology Engineering Solutions------Delivering Results

Low Pressure Xylene Recovery Column(XRC)

Single xylene recovery column =>

One stabilizer for isom + one xylene splitter

Operates at low (atmospheric) pressure and low

temperature => inherently safe design

High feed tolerance for light aromatics and heavy

aromatics

XRC side-draw vapor used for reboiling source or

steam generation

Low capex and opex

XRC reboiler can be steam reboiler or fired heater

XRC separates light aromatics and heavy aromatics from mixed xylenes feed

that are fed to pX crystallization section

• XRC Reboiler Duty :10-15% of SA unit xylene

column reboiler duty

• Steel Weight for XRC : approx. 1/8 of SA xylene

column and Stabilizer (Deheptanizer) for the

same pX capacity

No oxygen stripper/clay towers for imported feed

Page 13: Innovative Double Reslurry Technology for Paraxylene ... · A World of Solutions Innovative Double Reslurry Technology for Paraxylene Production 4th International Conference - Indian

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Double Reslurry Crystallization is the

CLEAR choice

Continuously improved for over 45 years

Lowest capex, opex and environmental emissions

Energy efficient

Ability to debottleneck or expand

Reliable

Page 14: Innovative Double Reslurry Technology for Paraxylene ... · A World of Solutions Innovative Double Reslurry Technology for Paraxylene Production 4th International Conference - Indian

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0

20

40

60

80

Heat ofvapourisation

Heat offusion

Hea

t, k

cal/

kg

Energy Advantage with Double Reslurry Crystallization

Freezing beats boiling

53% lower

$37 energy cost advantage

fuel at $60/MM kcal and electricity $0.10/kwh

Fuel $/MT pX

Power $/MT pX

Total $/MT pX

Crystallization Base Base Base

Selective Adsorption Base + $51 Base - $14 Base + $37

Energy reduction with Double Reslurry

Crystallization and optimized refrigeration

One low pressure xylene

recovery/stabilizer column

Environmental

emissions (SOx /

NOx) are proportional

to fuel usage-25% of

SA!

Page 15: Innovative Double Reslurry Technology for Paraxylene ... · A World of Solutions Innovative Double Reslurry Technology for Paraxylene Production 4th International Conference - Indian

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Double Reslurry Crystallization

Refrigeration power requirement

Double Reslurry Crystallization

+ 50% Reduction

Traditional 2 stage crystallization

Base

pX product

Xylenes

pX lean

xylene

Double Reslurry

pX crystallization

Centrifuge Centrifuge

Paraxylene is recovered as 99.8%+ product via Double Reslurry Crystallization and other

xylene isomers (oX/mX) and ethylbenzene are fed to isomerization

Double Reslurry Crystallization

Page 16: Innovative Double Reslurry Technology for Paraxylene ... · A World of Solutions Innovative Double Reslurry Technology for Paraxylene Production 4th International Conference - Indian

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Double reslurry crystallization is the

CLEAR choice

Continuously improved for over 45 years

Lowest capex, opex and environmental emissions

Energy efficient

Ability to debottleneck or expand

Reliable

Page 17: Innovative Double Reslurry Technology for Paraxylene ... · A World of Solutions Innovative Double Reslurry Technology for Paraxylene Production 4th International Conference - Indian

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0

100

200

300

400

500

600

700

2000 2004 2005 2011

Pla

nt

Ca

pa

cit

y, k

MTA

Original design

Centrifuge optimization

Debottleneck of isom recycle compressor and

isom heater

Ethylene refrigeration optimization

Revamp history for BP Geel plant, Belgium

420kMTA

500kMTA

575kMTA

675kMTA

Easy Expansion

No centrifuges, crystallizers or refrigeration

compressors added or replaced

Page 18: Innovative Double Reslurry Technology for Paraxylene ... · A World of Solutions Innovative Double Reslurry Technology for Paraxylene Production 4th International Conference - Indian

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Low cost expansion

Debottlenecks selective adsorption at lowest capex

Improve selective adsorption opex

Existing Double Reslurry Crystallization unit flexibility

Feed pX rich stream into later reslurry stage

Opportunity feed from STDP or other high purity pX stream

No additional processing steps

Minimal capex/opex capacity increase similar to Geel experience

Large capex and opex penalty for selective adsorption unit

High purity stream gets diluted when mixed with existing lower purity feed

Double Reslurry Debottlenecks

Page 19: Innovative Double Reslurry Technology for Paraxylene ... · A World of Solutions Innovative Double Reslurry Technology for Paraxylene Production 4th International Conference - Indian

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Double Reslurry Crystallization is Environmentally Friendly

Geel, Belgium

100m

Page 20: Innovative Double Reslurry Technology for Paraxylene ... · A World of Solutions Innovative Double Reslurry Technology for Paraxylene Production 4th International Conference - Indian

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Double Reslurry Crystallization is the

CLEAR choice

Continuously improved for over 45 years

Lowest capex, opex and emissions

Energy efficient

Ability to debottleneck or expand

Reliable

Page 21: Innovative Double Reslurry Technology for Paraxylene ... · A World of Solutions Innovative Double Reslurry Technology for Paraxylene Production 4th International Conference - Indian

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Double Reslurry Crystallization Has High Reliability

90

91

92

93

94

95

96

97

98

99

100

2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 Avg

99.1%

Actual Geel Reliability

A 4% higher reliability = 40,000 mta more production

= $ 15 million increase in gross margin per year for 1

MM MTA pX plant

Page 22: Innovative Double Reslurry Technology for Paraxylene ... · A World of Solutions Innovative Double Reslurry Technology for Paraxylene Production 4th International Conference - Indian

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Double Reslurry is the CLEAR choice

Continuously improved for over 45 years

Lowest capex, opex and emissions

Energy efficient

Ability to debottleneck or expand

Reliable

Page 23: Innovative Double Reslurry Technology for Paraxylene ... · A World of Solutions Innovative Double Reslurry Technology for Paraxylene Production 4th International Conference - Indian

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Copyright 2016, CB&I Inc. All rights reserved.


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