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Petrochemical Industry Overview A KEY VALUE CREATOR FOR THE HYDROCARBON CHAIN SANJEEV KAPUR PRINCIPAL CONSULTANT & PRESIDENT
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Page 1: Petrochemical Industry Overview - Rice Global E&C · PDF filePetrochemical Industry Overview A KEY VALUE CREATOR FOR THE HYDROCARBON CHAIN ... • On-purpose propylene capacity will

Petrochemical Industry OverviewA KEY VALUE CREATOR FOR THE HYDROCARBON CHAIN

SANJEEV KAPURPRINCIPAL CONSULTANT & PRESIDENT

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Biography

Sanjeev Kapur

Principal Consultant and President

Apex PetroConsultants, LLC

+1 713-632-5012

[email protected]

www.apexpetroconsultants.com

APEX PETROCONSULTANTS © 2

Sanjeev Kapur is an independent consultant in the field of olefins based petrochemical businesses.

He brings the value of strategic thinking, specific industry insights, knowledge and depth of

experience for olefins based petrochemical businesses to develop, build and operate best-in-class

facilities. Sanjeev has 35 years of industry experience and had been associated with Fluor, Shaw

Stone & Webster (now part of Technip), ABB Lummus Global (now CB&I Lummus), and The Kinetics

Technology International (now part of Technip). He has extensive experience working in the

licensing and engineering / construction industry. Most of this work has been in

ethylene/propylene-based petrochemical projects and integration of these with refineries, aromatic

production, natural gas processing, polymers, derivatives and specialty chemical units. Sanjeev

provides independent expert advice and impartial analysis to deliver value to the businesses to

realize their full potential.

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Agenda

Understanding the value chain

Industry fundamentals

Trends

Success factors & challenges

APEX PETROCONSULTANTS © 3

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Understanding the value chainApproximately 12% of crude oil and natural gas ends up in petrochemicals, the

multiplier effect makes it an important avenue for value creation

APEX PETROCONSULTANTS © 4

1

2

4

9

15

Crude Oil, Natural Gas Liquids & Natural Gas

PetrochemicalsFertilizers, Lubricants

Solvents, Sealants

Rubbers, Fibers, Paints

Base Chemicals

Plastic Resins

Plastic Products

Fuels88%

6%

6%

2%

~ Value Multiplier(Historical Typical)

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Energy to Base Chemicals

APEX PETROCONSULTANTS © 5

Coal

Natural Gas

Crude Oil

Off-gasesLPG

NaphthaGasoil

Olefins Plant

Aromatics Unit

Reformate

MethaneEthane

PropaneButane

Condensates

Methanol UnitSyn gas Methanol

Ethylene

Propylene

C4’s(Butadiene, Butylene)

Pygas(Benzene, Toluene, Xylene)

Benzene, Toluene, Xylene

Energy and Feedstock Base Chemicals

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Ethylene Value Chain

APEX PETROCONSULTANTS © 6

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Global Ethylene Demand - 2014

APEX PETROCONSULTANTS © 7

PE

VCM/PVC

EBSM

EO/EG

Others

PE

VCM/PVC

EBSM

EO/EG

Others

Total Demand: ~136 MM MTACapacity Utilization: 88%Expected AAGR (2030): ~3.3%

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Propylene Value Chain

APEX PETROCONSULTANTS © 8

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Global Propylene Demand - 2014

APEX PETROCONSULTANTS © 9

PP

Acrylonitrile

Cumene/Phenol

PO

Others

PP

Acrylonitrile

Cumene/Phenol

PO

Others

Total Demand: ~88 MM MTACapacity Utilization: 84%Expected AAGR (2030): 4.5%

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Typical Cost of Production - Chemicals

APEX PETROCONSULTANTS © 10

Feed

Utilities

Fixed

Cash Costs

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EIA Outlook – Crude and NG Prices

APEX PETROCONSULTANTS © 11

Source: www.eia.gov

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Shale Driven Growth – Petrochemical Industry

APEX PETROCONSULTANTS © 12

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Shale related investments in US chemical industry

APEX PETROCONSULTANTS © 13

Driven by Base Chemicals: Ethylene, Propylene (PDH), Methanol

Source: http://www.americanchemistry.com/Policy/Energy/Shale-Gas/Shale-Investment-Infographic.pdf

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Energy Market Dynamics

APEX PETROCONSULTANTS © 14

CO

ST O

F P

RO

DU

CTI

ON

ETHYLENE CAPACITY

$50 Brent $100 Brent

ME Ethane Crackers: $50 – 200/MT

NA Ethane Crackers:$100 – 350/MT

World Naphtha Crackers:$400-800/MT

World Naphtha Crackers: $900-1300/MT

Source: based on publically available data/costs

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World Ethylene Capacity

APEX PETROCONSULTANTS © 15

0

20

40

60

80

100

120

140

160

180

1990 1995 2000 2005 2010 2015 2020

Cap

acit

y, M

illio

n M

TA

Year

Capacity expected to grow at ~3.3% AAGR for next 15 years. An additional 100 million MTA ethylene may be needed by 2030.

Source: based on publically available data

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US Ethylene Capacity

APEX PETROCONSULTANTS © 16

Based on announced additions, US will add more than 50% capacity over 5 years

Source: GHS, Apex PetroConsultants, industry news sources

50.0

60.0

70.0

80.0

90.0

100.0

110.0

120.0

130.0

140.0

2014 2015 2016 2017 2018 2019 2020 2021 2022 2023

Bill

ion

Po

un

ds

pe

r Ye

ar

Grasss-rootAdditions

Expansions/Increments

Basecapacity

US EthyleneCapacity(Billion Lbs)

Speculative

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World Propylene Demand

APEX PETROCONSULTANTS © 17

20

40

60

80

100

120

140

160

180

2000 2005 2010 2015 2020 2025 2030

Cap

acit

y, M

illio

n M

TA

Year

Expected

Source: based on publically available data

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PDH (Propane Dehydrogenation) Capacity Additions

APEX PETROCONSULTANTS © 18

0

2

4

6

8

10

12

2014 2015 2016 2017

Bill

ion

Po

un

ds

Per

Year

Korea

China

USA

Source: GHS, Apex PetroConsultants

Based on announced capacity additions in North America and Asia

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Petrochemical Industry – Top Trends

APEX PETROCONSULTANTS © 19

• Shale driven growth

• Alternate feedstock - Coal to a large extent, potentially bio/renewables

• Middle East feed diversification, breadth of product coverage

• Demand growth – led by China, India, Brazil, Turkey, Mexico etc.; growing middle class

and urbanization; growth of construction sectors/ automobile and packaging industry

• Energy market dynamics – crude oil prices relative to natural gas and coal

• Technology & Innovation - On-purpose technologies for C3s, C4s and aromatics; material

advances (lightweight, nanomaterials, functional textiles etc.)

• Environmental - Greenhouse gas emissions regulations, water management,

recycling/waste treatment

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Success Factors

Petrochemical Business Success Factors

APEX PETROCONSULTANTS © 20

Access to feed, markets, and

resources

World scale, integrated, and

competitive

Technology, product range

coverage

Global coverage

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World Scale Ethylene Plant Capacity Trend

APEX PETROCONSULTANTS © 21

0

200

400

600

800

1000

1200

1400

1600

1965 1970 1975 1980 1985 1990 1995 2000 2005 2010 2015 2020

Cap

acit

y, k

MTA

Year

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Ethylene Cracker Complexes – Mega Projects

APEX PETROCONSULTANTS © 22

• Mature technology, access to cheap feed-stock cost and the market is critical

• Robust business case development - master planning is crucial

• Integration is the key - hydrocarbon management, energy integration, synergies

• Successful delivery of mega capital projects

• Capital efficiency, project costs, timely start-up and quick ramp-up to full capacity

• Economics of large scale projects are based on long-term outlook (20 to 30 years is

typical) – feed security is important

• Regulatory uncertainty – permitting, taxation, trade barriers, environmental regulations

• Technical and skilled resources

• Access to financing, financing structure

Planning is vital

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Propane Dehydrogenation (PDH) Plants

APEX PETROCONSULTANTS © 23

• Technology is not as mature and as widely used as ethylene crackers

• Propylene is transitioning from by-product/co-product production to more on-

purpose & will be subjected to cyclical nature of the industry

• On-purpose propylene capacity will more than double in next 5 years

• PDH plants, and other on-purpose technologies for propylene, will become swing

producers and price setters

• Propane-propylene spread is the major driver of economics (propane price is

subjected to seasonal variations)

• Propylene margins diverge on regional basis

• North America: positive PDH economics due to excess propane supplies

• Overcapacity in Asian plants

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Disclaimer

APEX PETROCONSULTANTS © 24

All information (“Information”) contained herein is intended to be general in nature. You should not rely on it in making any decision. Nothing in this presentation constitutes a representation that any recommendation contained herein is suitable or appropriate to a recipient’s individual circumstances or otherwise constitutes a personal recommendation. It is presented solely for information purposes. The opinions and the markets are subject to change. Apex PetroConsultants accepts no responsibility for results obtained by the application of this Information, and disclaims all liability for all damages. With regard to Apex PetroConsultants, to the extent the user is entitled to disclose and distribute this document, the user may forward, distribute, and/or photocopy this copyrighted document only if unaltered and complete, including all of its headers, footers, disclaimers, and other information. You may not copy this document to a Web site. Apex PetroConsultants prohibits the redistribution of this material in whole or in part without the written permission of Apex PetroConsultants and Apex PetroConsultants accept no liability whatsoever for the actions of third parties in this respect.


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