Sadara Corporate Awareness

CORPORATE AWARENESS

Corporate awareness. Learn more about Sadarawww.sadara.com

What we do and how we do it.

Contents

1 Introduction +

2 Map +

3Feed Stock +Raw material required for an industrial process.

Product +The product that emerges at the end of a manufacturing process; Sadara Products.

5

6

Process + Insights on the mechanisms and technologies Sadara implements to produce intermediate goods and Sadara Products.

4

Intermediate +An intermediate good is a good that is used in the eventual production of a final good, or finished product.

CONTENTS MAP FEED STOCK INTERMEDIATE PRODUCT PROCESS GLOSSARYINTRO

Introduction

Sadara is a joint venture developed by the Saudi Arabian Oil Company (Saudi Aramco) and The Dow Chemical Company. With a total investment of about $20 billion, Sadara is building a world scale chemical complex in Jubail Industrial City II in Saudi Arabia’s Eastern Province.

Comprising 26 world scale manufacturing units, the Sadara complex is the world’s largest to be built in a single phase and will be the first in the Middle East to use refinery liquids, such as naphtha, as feedstock. Sadara will enable many industries that either currently do not exist in Saudi Arabia or only exist through imports of raw materials.

The adjacent PlasChem Park, a unique collaboration between Sadara and the Royal Commission for Jubail and Yanbu, will create more value downstream, generating unprecedented investment, innovation, economic growth and thousands of jobs.

The company name derives from the Arabic word for “at the forefront” or “leading”.

More information about Sadara can be found at www.sadara.com

START

BASICS

WITH

THE

CONTENTS INTRO MAP FEED STOCK INTERMEDIATE PRODUCT PROCESS GLOSSARY

Saudi Aramco, a fully integrated, global petroleum and chemicals enterprise, is the state-owned oil company of the Kingdom of Saudi Arabia.Saudi Aramco has became a world leader in hydrocarbons exploration, production, refining, distribution, shipping and marketing, and the world’s top exporter of crude oil and natural gas liquids (NGLs).

More information about Saudi Aramco can be found at www.saudiaramco.com

Introduction

START

BASICS

WITH

THE


Introduction

Dow combines the power of science and technology to passionately innovate what is essential to human progress. The Company is driving innovations that extract value from the intersection of chemical, physical and biological sciences to help address many of the world’s most challenging problems such as the need for clean water, clean energy generation and conservation, and increasing agricultural productivity.

Dow’s integrated, market-driven, industry-leading portfolio of specialty chemical, advanced materials, agrosciences and plastics businesses delivers a broad range of technology-based products and solutions to customers in approximately 180 countries and in high growth sectors such as packaging, electronics, water, coatings and agriculture. In 2013, Dow had annual sales of more than $57 billion and employed approximately 53,000 people worldwide.

The Company’s more than 6,000 products are manufactured at 201 sites in 36 countries across the globe.

More information about Dow can be found at www.dow.com.

START

BASICS

WITH

THE


H2

FEED STOCK INTERMEDIATE PRODUCT PROCESS

ANILINE

PG

MDI

LLDPE X2

LDPE

BUTANOL

H2O2

BGE

EAE

HCI Cl2

TDIDNT TDA

ETHYLENE

ETHANE

NAPHTHA

MeOH

HCl

C4S

PYGAS

NH3

NaOH2

NaCl

BENZENE MNB

PO

Cl2 NaOH

POLYOLS

EO

ELASTOMERS

NH3

AROMATICSHYDROGENATION

& EXTRACTION

PROPYLENE

TOLUENE

HNO3

Interact with the chart below:

IMPORTED TOLUENE

IMPORTED BENZENE

EOA

CO

NH3 MIXED FEED CRACKER

FORMALIN

CONTENTS MAP FEED STOCK INTERMEDIATE PRODUCT PROCESS GLOSSARYINTRO

Feed Stock

Ethane +

Naphtha +

Butanol +

Hydrogen Peroxide +

Nitric Acid +

Ammonia +

Formalin +

Raw material required for an industrial process.

FeedStock

FeedStock

FeedStock

FeedStock

FeedStock

CONTENTS FEED STOCKMAP INTERMEDIATE PRODUCT PROCESS GLOSSARYINTRO

Application Source

• Ethane can be used as a fuel.

• In Sadara, Ethane is fed into a steam cracker to produce Ethylene.

• Ethane is the second-largest component of natural gas.

• Sadara gets the Ethane by pipeline from the Saudi Aramco Ethane grid.

• Ethane will be fed into Mixed Feed Cracker

Ethane is a hydrocarbon compound that exists in nature as an odorless and colorless gas at standard temperature and pressure.

Ethane is isolated on an industrial scale from natural gas, and as a byproduct of petroleum refining.

C2H6

Ethane


• Naphtha is produced from crude oil.

• Sadara gets the Naphtha by pipeline from SASREF.

• Naphtha is used primarily as feed stock for producing Ethylene and Propylene.

Naphtha is a hydrocarbon. It is a colorless to reddish-brown volatile aromatic liquid, very similar to gasoline.

Naphtha

Application Source


• Sadara gets Butanol by pipeline from the Saudi Butanol Company.

• The primary uses of Butanol are as a solvent; as an intermediate in chemical synthesis; and as a fuel.

• In Sadara, Butanol is used as a raw material to produce BGE, Butyl Glycol Ether.

Butanol is a colorless, toxic liquid.

C4H9OH

Butanol

Application Source


• Sadara gets Hydrogen Peroxide by pipeline from the Jubail Hydrogen Peroxide plant.

• Hydrogen peroxide is often used as a bleach or cleaning agent.

• In Sadara H2O2 is used to produce Propylene Oxide (PO).

Hydrogen Peroxide is a clear liquid, which is slightly more viscous than water. It is also a strong oxidizer.

H2O2

Application Source

Hydrogen Peroxide


• Sadara gets Ammonia from Linde (on-site plant).

• Sadara will use Ammonia, Carbon Monoxide, and Hydrogen primarily for the production of Isocyanates (MDI and TDI) and Amines.

NH3

Ammonia

Application Source

Ammonia is a colorless gas with a characteristically pungent smell.


Nitric Acid (HNO3), is also known as aqua fortis and spirit of niter, it is a highly corrosive and strong mineral acid. The pure compound is colorless.

• Sadara gets Nitric Acid from the supply of Ammonia which comes from the on-site Linde Plant.

• HNO3 is produced in the Nitric Acid Plant.

• Nitric Acid is used to produce Mono Nitro Benzene (MNB) and Di Nitro Toluene (DNT) for manufacturing TDI and MDI.

HNO3

Nitric Acid

Application Source


Application

• Formalin is a common precursor to more complex compounds and materials. In Sadara it is used to produce Methylene Diphenyl Diisocyanate (MDI).

CH2O

Source

• Sadara gets Formalin from the Methanol (MeOH) that comes from SABIC.

• Formalin is produced in the Formalin plant.

Formalin is a clear, colorless, aqueous solution of 40% formaldehyde, 8% methyl

alcohol and 52% water.

It is an organic compound, and has a characteristically pungent, irritating odor. It is an important precursor to many other materials and chemical compounds. It is commonly used in nail hardeners and nail varnish.

It is made in the Formalin unit.

Formalin


An intermediate is a substance that is used in the eventual production of a finished product.

Ethylene + Aniline +

Propylene + Di Nitro Toluene +

Benzene + Toluene Di Amine +

Toluene + Chlorine +

Ethylene Oxide + Hydrochloric Acid +

Propylene Oxide + Sodium Hydroxide +

Mono Nitro Benzene +

Intermediate

CONTENTS INTERMEDIATEMAP FEED STOCK PRODUCT PROCESS GLOSSARYINTRO

Ethylene (H2C=CH2) is a colorless, flammable gas with a faint ‘sweet and musky’ odor when pure.

H2C=CH2

Ethylene

Application Source

• Ethylene is produced in the petrochemical industry by cracking (Process of breaking large hydrocarbon molecules into smaller molecules). Sadara uses a Mixed Feed Cracker to crack Naphtha and Ethane to get Ethylene.

• In petrochemicals, it’s used in manufacturing Polyethylene plastics, such as LLDPE and LDPE.


Propylene (C2H6) is also known as Propene. At room temperature and atmospheric pressure, Propylene is a colorless gas with a weak but unpleasant smell.

C2H6

Propylene

Application Source

• Propylene is produced in the petrochemical industry by cracking. Sadara uses a Mixed Feed Cracker to crack Naphtha and Ethane to get Propylene.

• Essentially all of the Propylene produced for chemical purposes is consumed as a chemical intermediate in other chemical manufacturing processes.

• In Sadara Propylene is used to produce Propylene Oxide (PO).


Benzene (C6H6) is a colorless and highly flammable liquid with a sweet smell. It evaporates quickly when exposed to air.

C6H6

Benzene

Application Source

• Benzene comes in a non-purified form through a pipeline from SASREF. It will go under a process within the Aromatics fa-cility ** (Aromatics are a group of organic compounds which include Benzene) to be converted into a very high-purity Ben-zene and used as feed stock by the Isocy-anates production unit.

• Benzene is used mainly as a feedstock to make other chemicals. It has been used in, or used to manufacture, a wide variety of chemical products. In Sadara Benzene is used to produce Mono Nitro Benzene (MNB).


Toluene (C7H8) is a clear, water-insoluble liquid with the typical smell of paint thinners.

C7H8

Toluene

Application Source

• Toluene comes from Ras Tanura. It will go under a process within Aromatics to be converted into a very high-purity Toluene and used as feed stock by the Isocyanates production unit.

• Toluene is an aromatic hydrocarbon that is widely used as an industrial feed stock to produce Toluene Diisocyanate (used in the manufacture of polyurethane foam).


Ethylene Oxide (C2H4O) is a colorless, flammable gas at room temperature, with a faintly sweet odor.

C2H4O

Ethylene Oxide

Application Source

• Ethylene Oxide is manufactured by the direct oxidation of Ethylene with high-purity oxygen.

• Ethylene Oxide is used as an Intermediate product to produce Butyl Glycol Ether (BGE), Ethanolamine, Ethyleneamine, and Polyols.


Propylene Oxide (PO) is a highly reactive, colorless, highly flammable, liquefied organic compound.

Propylene Oxide

Application Source

• The industrial production of Propylene Oxide comes from the oxidation of Propylene.

• PO is made by a technology jointly owned by BASF and Dow.

• Propylene Oxide is used for the production of Polyether Polyols for making polyurethane plastics. It is also used to produce Propylene Glycol (PG).

CH3CHCH2O


Mono Nitro Benzene (MNB) is produced by the nitration of Benzene, which minimizes the formation of Nitrophenols and Dinitrobenzene byproducts.

MNB will be made by NORAM technology.

Mono Nitro Benzene

Source

• Mono Nitro Benzene, obtained from Benzene and Nitric Acid in the presence of Sulphuric Acid by the adiabatic process, is the starting material for Aniline, which is a valuable raw material for the plastics chemistry, MDI.

Application

• Mono Nitro Benzene is converted to Aniline, which is subsequently used to produce Methylene Diphenyl Diisocyanate (MDI). MDI is copolymerized with various Polyols to form polyurethane.

C6H5NO2


• Aniline is manufactured by hydrogenating Mono Nitro Benzene.

• It will be produced in the Aniline Plant.

• Aniline is used to produce Methylene Diphenyl Diisocyanate (MDI). MDI is copolymerized with various Polyols to form polyurethane.

C6H5NH2

Aniline (C6H5NH2), also known as Phyeylamine or Aminobenzene, is a colorless, oily and slighty water-soluble liquid. It is toxic and, like most volatile amines, possesses the odor of “rotten fish”. It ignites readily, burning with a smoky flame that is characteristic of aromatic compounds.

Application Source

Aniline


Di Nitro Toluene (DNT) is a pale yellow crystalline solid.

Di Nitro Toluene

Application Source

• DNT is produced in the DNT plant that mixes Toluene with Nitric Acid.

• Di Nitro Toluene is well known as a precursor to Trinitrotoluene (TNT) but is mainly produced as a precursor to Toluene Diisocyanate (TDI).

C7H6N2O4


Toluene Di Amine (TDA) is a colorless solid that tends to darken on storage and exposure to air. Nearly all of the TDA produced is used as part of a mixture for the production of TDI.

Toluene Di Amine

Application Source

• TDA is manufactured by Dow Technology by nitrating Toluene to produce Di Nitro Toluene, which is then catalytically reduced to TDA.

• TDA is used to manufacture TDI by the reaction with Carbonyl Chloride (Phosgene).


Chlorine (Cl2) is a chemical element with the symbol Cl and atomic number 17 (Atomic number Equal to the number of protons in a given element).

At standard temperature and pressure, two Chlorine atoms form the diatomic molecule Cl2 (Diatomic: Molecule composed of two atoms). Chlorine is a yellow-green gas that is highly toxic when exposed to directly.

Chlorine

Application Source

• Sadara gets Cl2 from the Chlorine plant.• Chlorine is used in the production of a wide range of industrial and consumer products. In Sadara it is used to produce MDI (Methylene Diphenyl Diisocyanate) and TDI (Toluene Di Amine).

Cl2


Hydrochloric Acid is a clear, colorless solution of Hydrogen Chloride (HCl) in water. It is a highly corrosive, strong mineral acid with many industrial uses.

Hydrochloric Acid

Application Source

• Hydrochloric Acid is used in the chemical industry as a chemical reagent in the large-scale production of MDI/TDI for polyurethane.

• HCI is produced as a byproduct from PMDI (Polymeric Methylene Diphenyl Diisocyanate) and TDI then recycled back to the HCl plant to produce Chlorine (Cl2).


Application

Sodium Hydroxide (NaOH), is also known as lye or caustic soda. It is a highly caustic metallic base and alkaline salt. It is a white solid available in pellets.

NaOH

Source

Sodium Hydroxide

• Sodium Hydroxide is the principal strong base used in the chemical industry. In Sadara’s production line it is used to produce MNB (Mono Nitro Benzene) and MDI.

• NaOH is provided by the Chlor-Alkali unit.


These are the final Sadara products that emerge at the end of the manufacturing processes.

Linear Low-Density Polyethylene + Propylene Glycol +

Low-Density Polyethylene +

Elastomers + Toluene Diisocyanate +

Butyl Glycol Ether + Ethanolamin +

Polyols + Ethyleneamine +

Product

Polymeric Methylene Diphenyl Diisocyanate +

CONTENTS PRODUCTMAP FEED STOCK INTERMEDIATE PROCESS GLOSSARYINTRO

Application Source

• LLDPE is used for plastic bags and sheets (where it allows using lower thickness than comparable LDPE), plastic wrap, stretch wrap, pouches, toys, covers, lids, pipes, buckets and containers, covering of cables, and flexible tubing.

• LLDPE is produced by copolymerization of Ethylene with alpha-olefins such as Butene, Hexene, or Octene.

Linear Low-Density Polyethylene (LLDPE) is a substantially linear polymer (polyethylene), with significant numbers of short branches.

Sadara capacity is 750 KTA.

SINGLE MIXED FEED CRACKER ETHYLENE LLDPE

Linear Low-Density Polyethylene


Application Source

• LDPE is widely used for manufacturing various containers, dispensing bottles, wash bottles, tubing, plastic bags for computer components, and various molded laboratory equipment. LDPE’s most common use is in plastic bags.

• LPDE is made by a high-pressure process via free radical polymerization of Ethylene.

Low-Density Polyethylene (LDPE) is a thermoplastic made from the monomer Ethylene. It is the first grade of polyethylene.


SINGLE MIXED FEED CRACKER ETHYLENE LDPE

Low-Density Polyethylene


Application

• Sadara will have different grades of elastomers, each for use in different markets and applications. These include: - Adhesives

- Consumer solutions

- Health & hygiene

- Building & construction

- Footwear

- Automotive.

Elastomers are a formation of a thermoplastic or thermoset that can stretch and then return to its original shape without permanent deformation. Elastomers are only slightly cross-linked.

Sadara capacity is 220 to 270 KTA.

SINGLE MIXED FEED CRACKER ETHYLENE ELASTOMERS

Source

• Elastomers are made by a high-pressure process via free radical polymerization of Ethylene.

Elastomers


Application

Butyl Glycol Ether (BGE) is a colorless, mild-smelling liquid with a high boiling point.


Source

SINGLE MIXED FEED CRACKER ETHYLENE EO BGE 3RD PARTY BUTANOL

Butyl Glycol Ether

• Glycol Ethers are used as solvents for resins, lacquers, paints, varnishes, gum, perfumes, dyes, inks, as a constituent of paints and pastes, cleaning compounds, liquid soaps, cosmetics, and hydraulic fluids.

• Glycol Ether products are produced in the BGE unit through continuous processes of selectively reacting an alcohol and Ethylene Oxide.


Application

Polyol is an alcohol with more than two reactive hydroxyl groups per molecule.


Source

SINGLE MIXED FEED CRACKER PROPYLENE PO POLYOLS

Polyols

• By mixing Polyol with TDI or MDI in the presence of suitable catalysts and additives, we can get polyurethane.

• Polyurethane applications include:

- Flexible foams

- Rigid foams

- Non-foamed products.

• Polyols products are produced through batch processes of selectivity reacting Propylene Oxide and Ethylene oxide.

• Butyl Glycol Ethers unit.


SINGLE MIXED FEED CRACKER PROPYLENE PO PG

Application

• 45% of Propylene Glycol produced is used as chemical feed stock for the production of unsaturated polyester resins, which can be used in the following markets and applications:

- Pharmaceutical

- Pet food

- Food and flavorings

- Paint and coatings

- Urethanes

- Aircraft deicing fluid

- Heat transfer fluid / thermal fluids

- Hydraulic and brake fluid

- Coolants and antifreeze

- Unsaturated polyester

- Fragrance and Personal Care.

Propylene Glycol (PG) is a colorless, nearly odorless, viscous liquid with a faintly sweet taste, and is hygroscopic and miscible with water, acetone, and chloroform.


Source

• Propylene Glycol is produced from Propylene Oxide.

• The new PG facility will use Dow’s proprietary technology.

Propylene Glycol


Application

• Rigid polyurethanes such as sandwich panels and cold stores.

Polymeric Methylene Diphenyl Diisocyanate (PMDI) is the predominant Isocyanate used in rigid polyurethane manufacture. Otherwise standard mixtures of MDI/PMDI are used in urethane production and essentially all MDI/PMDI is used in the manufacture of normal polyurethanes.


Source

• The first step of the production of PMDI is the reaction of Aniline and Formalin, using Hydrochloric Acid as a catalyst.

• PMDI unit.

AROMATICS HYDROGENATION & EXTRACTION BENZENE MNB ANILINE PMDI FORMALIN

Polymeric Methylene Diphenyl Diisocyanate


Application

• By mixing Polyol with Toluene Diisocyanate (TDI), we can get flexible foams which can be used in mattresses and furniture.

Toluene Diisocyanate (TDI) is an organic compound produced in large scale production for Polyurethane. It is a colorless, yellow, or dark liquid with a sharp, pungent odor.


Source

• TDI is manufactured by the reaction of TDA & Clarion gas.

• TDI is made by Dow Phosgenation Technology.

AROMATICS HYDROGENATION & EXTRACTION TOLUENE DNT TDA TDI

Toluene Diisocyanate


Application

• It is used in aqueous solutions for scrubbing certain acidic gases. It is used as feed stock in the production of detergents, emulsifiers, polishes, pharmaceuticals, corrosion inhibitors, and chemical intermediates.

Ethanolamine (EOA) is a toxic, flammable, corrosive, colorless, viscous liquid with an odor similar to that of Ammonia.


Source

• Ethanolamine is produced in the(EOA) unit by reacting Ethylene Oxide with aqueous Ammonia.

ETHYLENE EO ETHANOLAMINE NH3SINGLE MIXED FEED CRACKER

Ethanolamine


Application

• Ethyleneamine is used for:

- Asphalt additives

- Corrosion inhibitor

- Elastomeric fibers

- Fabric softeners

- Pharmaceuticals

- Plastic lubricants

- Rubber processing additives

- Lube oil and fuel additives.

Ethyleneamine (EAE) is a colorless and highly corrosive liquid. it mixes well with organic solvents and water.

Sadara capacity is 45 KTA

• Ethyleneamine is produced in the(EOA) unit by reacting Ethylene Oxide with aqueous Ammonia.

ETHYLENE EO ETHYLENEAMINE NH3SINGLE MIXED FEED CRACKER

Ethyleneamine

Source


MAP FEED STOCK INTERMEDIATE PRODUCT GLOSSARYINTRO

Mixed Feed Cracker +

Aromatics +

ProcessInsights on the mechanisms and technologies Sadara implements to produce intermediate goods and Sadara Products.

Isocyanates +

Mono Nitro Benzene +

Hydrochloric Acid +

Di Nitro Toluene +

Chlor-Alkali +

Nitric Acid +

Aniline +

Toluene Di Amine +

Formalin +

Polymeric Methylene Diphenyl Diisocyanate +

Chemicals +

Ethylene Oxide +

Ethanolamine and + EthyleneamineButyl Glycol Ethers +

Propylene Oxide +

Propylene Glycol +

Polyols +

Plastics +

Polyethylene Trains + 1,2 & 4

HP-LDPE Train 3 +

Toluene Diisocyanate +

CONTENTS PROCESS

CONTENTS PROCESSMAP FEED STOCK INTERMEDIATE PRODUCT GLOSSARYINTRO

• MFC, the heart of Sadara, will utilize a Mixed Feed Cracker that is licensed from Technip, with a designed feed rate of 85 MMSCFDM (million standard cubic feet per day) of Ethane and 51,000 barrels per day of Naphtha. The unit will be equipped with 12 furnaces: seven will be dedicated to Ethane (gas) and five to Naphtha (liquid). The feed stock will be converted into 1.5 million tons per year of Ethylene and 400,000 tons per year of Propylene. The cracker provides additional products for the Sadara complex including Pygas. The Pygas contains Benzene and Toluene which will be refined in the Aromatics plant. Hydrogen and Methane off-gas are also produced and used within the Sadara site as fuel.

Mixed Feed Cracker


• The Aromatics facility comprises of two process technologies to extract the aromatics from Pygas feed stock: The front end of the facility, which will use a Pygas Hydrogenation process (first and second stage hydrogenation); and the back end of the facility, which will use an Extraction Distillation process.

(Hydrogenation: A chemical reaction between hydrogen and another chemical, usually in the presence of a catalyst.)

(Extraction Distillation: Process to extract a chemical from a mixture that, due to the chemical’s low volatility, cannot be extracted through a simple distillation process. A solvent is added to raise the volatility of the chemical, so that it can be extracted through distillation – check definitions)

Shaw will provide technology for the Pygas Hydrogenation process (with BASF reactor design and catalyst) while GTC will provide technology for the Extractive Distillation process. The plant will have a design capacity of 275,000 tons per year of Benzene and 131,000 tons per year of Toluene. Additional Benzene and Toluene will be needed for the planned capacities of the downstream plants such as Mono Nitro Benzene (MNB) and Di Nitro Toluene (DNT) plants and these will be sourced from third parties.

• The Aromatics units will take the MFC-produced Pygas feed, as well as purchased chemical-grade Benzene and Toluene, and convert them into very high-purity Toluene and Benzene for use as feed stock by the Isocyanates production units.

Aromatics


• Plastics is a complex manufacturing unit consisting of four trains which produce Polyethylene in a wide grade portfolio; like LLDPE, LDPE and Elastomers.

Plastics


Polyethylene Trains 1,2 & 4

• Polyethylene trains will use Dow’s proprietary Solution Polyethylene Most Effective Technology. The reaction is conducted in a solvent carrier. Ethylene and another compound such as Butene, Hexene, or Octene are fed to the reactor along with Hydrogen and the carrier solvent. A catalyst is injected into the reactor to initiate the polymerization reaction.

Following the reaction, the catalyst is deactivated, additives are introduced and the polyethylene is separated from the solvent. The recovered solvent is recycled back to the reactor along with un-reacted recycled Ethylene.

The polymer is converted into pellets and forwarded to storage silos and bagging (Solution PE trains) or directly to packaging (Elastomers). Trains 1 and 2 will have a combined design capacity of 750 KTA of LLDPE products, while Train 4 will have a design capacity of 220–270 KTA of Elastomer materials.

If there is a replica of a plant it is called a train. A train is used to produce the same product as a specific plant.


HP-LDPE Train 3

• The Tubular High Pressure Polyethylene process technology is based on the free radical polymerization at very high pressures initiated by Organic Peroxides. Telomers are used to control polymer molecular weight. Co-monomers can be used to obtain special properties. The process is heavily mechanical in nature. The Polymer is separated in two stage steps. The un-reacted materials are recycled to the Compression area where they join the fresh raw materials and a mixture is compressed back to a high-pressure reactor. The molten polymer stream from the separators is pelletized and transferred to storage. Additives can be added to the product. The plant capacity is highly dependent on the actual product mix and can vary in the range of 350 KTA.

(Polymerization: Reacting simple molecules together to form long molecule chains)

(Free radicals: Atom or ions which react rapidly, sometimes forming polymer chains.)


• The Chemicals unit is a complex manufacturing unit that consists of two sections: Ethylene Oxide Derivatives (EOD), and Propylene Oxide Derivatives (POD), with seven units to produce a number of main products.

Chemicals


Ethylene Oxide

• Ethylene Oxide is manufactured by the direct oxidation of Ethylene with high-purity oxygen. Ethylene and Oxygen are combined with methane and fed into a single Ethylene Oxide reactor. The methane is added as ballast to help control the oxidation reaction. The design for the Sadara project is a 360,000 tons per year standalone Ethylene Oxide plant.


Ethanolamine and Ethyleneamine

• Dow will provide technology for the integrated Ethanolamines (EOA) and Ethyleneamines (EAE) technologies. The EOA/EAE plant will have a combined design capacity of 255,000 tons per year. The EOA plant will be fed Ethylene Oxide produced on site and Ammonia produced by the on-site third party plant. The plant will produce Monoethanolamine (MEA), Diethanolamine (DEA), and Triethanolamine (TEA) will be produced in changeable production ratios.

The back end integrated EAE plant will be fed MEA produced on site from the EOA plant along with Ammonia and excess Hydrogen for the production of Ethylenediamine (EDA), Diethylenetriamine (DETA), Piperazine (PIP), and EAE heavy products.


Butyl Glycol Ethers

• The design for the Sadara project is a 200,000 tons per year Butyl Glycol Ethers plant. The process unit comprises two steps: (1) Glycol Ethers synthesis reaction and Butanol recovery and (2) product refining.

The reaction step involves the reaction of Ethylene Oxide and Butanol with Sodium Hydroxide as a catalyst to produce a range of Glycol Ether products. Fractional distillation is then used to obtain products. (Fractional distillation: The separation of a mixture into its component parts.) The process can produce both light and heavy mixtures of Glycol Ether products. The light mixture maximizes Monobutoxyglycol (EB) production, which will yield a specific EB to Dibutoxyglycol (DB) ratio. The heavy mixture maximizes production of the heavier Glycol Ethers to yield a lower EB to DB ratio. The process can operate to produce any mixture specification within this regime.


Propylene Oxide

• Dow plans to use its Hydrogen Peroxide-based Propylene Oxide (HPPO) technology jointly owned by BASF and Dow for the manufacturing of Propylene Oxide as part of the Sadara project. The plan will have a capacity of 390,000 tons per year using a single production line. Propylene feed stock will be supplied by the Cracker unit in the same project, while Hydrogen Peroxide (H2O2) will be supplied by the Hydrogen Peroxide plant to be constructed adjacent to the PO plant by a Sadara–Solvay joint venture.

• Crude Hydrogen Peroxide, Methanol, polymer-grade Propylene and an aqueous buffer are fed to the main reactor to convert H2O2 and Propylene to PO. In the intermediate PO-removal, PO and the excess Propylene (lights) are separated by distillation to protect PO from consecutive reactions. The bottom product consists of Methanol, water and H2O2 etc. which is sent to a secondary epoxidation reactor, where Propylene is added to increase the H2O2 conversion.


Propylene Glycol

• The Propylene Glycol (PG) facility will use proprietary Dow technology to achieve advanced energy reductions and throughput optimization. The design for the Sadara project is a 70,000 tons per year PG plant.

• The basic reaction is between Propylene Oxide and water. The hydration takes place in two stages followed by dehydration and purification. The reaction between PO and water requires a precise amount of water to favor PG production. The reaction mixture is dehydrated by evaporation and the various Glycols (Mono Propylene Glycol or MPG, Di-Propylene Glycol or DPG and Tri-Propylene Glycol or TPG) are separated by distillation.


Polyols

• Sadara will be using two different technologies to produce 400,000 tons per year of Polyether Polyols. A batch process will produce 70,000 tons per year of Potassium Hydroxide (KOH) catalyst plant for Polyols moulded (for use in rigid end-products) and a continuous 330,000 tons per year of DMC catalyst for Polyols slab (for flexible end-products) integrated with Propylene Oxide and Ethylene Oxide feed stocks.

• In the KOH process Sadara will produce low molecular weight Polyols, which will serve as an intermediate building block for the high molecular weight products. The reaction goes through two separate Oxide feed and digestion cycles. The Oxide type (Propylene or Ethylene Oxide), charge amount, reaction temperature and digestion time/temperature depend on the specific product to be manufactured. After the digestion step, the product is pumped to the crude Polyol rundown tank that serves as a buffer between the reaction and purification processes.


• Isocyanates is a complex manufacturing unit consisting of two sections with a number of units to produce two main products: PMDI (Polymeric Methylene Diphenyl Diisocyanate) section and TDI (Toluene Diisocyanate) section.

Isocyanates


• Uhde has been selected to provide its latest electrolysis technology for the Hydrochloric Acid (HCl) to Chlorine process to the Sadara project.

• The plant will have a capacity of 432,000 tons per year. It will be fed by the Hydrochloric Acid byproduct of the Isocyanate units. The pure Chlorine gas resulting from the HCl electrolysis will be recycled to both the PMDI and TDI units.

Hydrochloric Acid


• Dow will be providing its technology for the Chlor-Alkali (Cl2-NaOH) process to the Sadara project. The plant will have a capacity of 115,000 tons per year. It will be fed by salt imported to the site while the Chlorine and Caustic soda products will be fed downstream to the Polymeric Methylene Diphenyl Diisocyanate (PMDI) and Toluene Diisocyanate (TDI) facilities.

Chlor-Alkali


• The Mono Nitro Benzene (MNB) plant is a single train continuous operating unit that will be mainly feeding on Benzene from aromatics and Nitric Acid (65%). The MNB produced is stored in ISBL tanks and is routed to the Aniline plant for Aniline production.

• NORAM will provide technology for the MNB process. The plant, composed of three trains, will have a capacity of 416,000 tons per year and will be fed by the Nitric Acid and Benzene produced on site while the MNB product will be fed into the downstream Aniline plant.

Mono Nitro Benzene


• Josef Meissner GmbH & Co. KG will license its technology for the Di Nitro Toluene (DNT) process for the Sadara project. The technology package includes the NACSAC® process. It’s a sub-licence from Plinke, used to produce higher concentration Nitric Acid by utilizing Sulphuric Acid. The DNT plant will have an instantaneous design capacity of 250,000 tons per year and will be fed Toluene from the aromatics Hydrogenation and extraction unit. The Nitric Acid will be produced in-situ along with third party sourced Sulphuric Acid, while the DNT product will be fed downstream for Toluene Diamine (TDA) production.

Di Nitro Toluene


• The Nitric Acid plant is a single train continuous operating unit with dry Ammonia as feed to the unit producing Nitric Acid (65%). The plant has two consumers in the Isocyanates envelope: Mono Nitro Benzene (MNB) and Di Nitro Toluene (DNT) plants. Nitric Acid is transferred to an ISBL tank and stored prior to consumption in MNB. Nitric Acid is concentrated to 98%, prior to feeding the DNT plant.

• Espindesa, a subsidiary of Tecnicas Reunidas, will be licensing its dual pressure technology for the Nitric Acid (HNO3) process. It’s to be implemented with a plant design capacity of 400,000 tons per year. The process will be fed by Ammonia to be produced from an on-site third party Ammonia plant, while the Nitric Acid product will be fed downstream to the Mono Nitro Benzene (MNB) and Di Nitro Toluene (DNT) plants.

Nitric Acid


• DuPont/KBR will be providing its technology for the Aniline process to the Sadara project. The plant will have a total capacity of 300,000 tons per year and will be fed by the MNB produced in-situ, and hydrogen will be provided from the Syngas unit.

Aniline


• The plant is to be designed with an instantaneous design rate of 160,000 tons per year and will be fed Di Nitro Toluene (DNT) in-situ by an integrated upstream Toluene nitration process unit, while the TDA product from the Hydrogenation process will be fed downstream for Toluene Diisocyanate (TDI) production by Phosgenation. The TDA technology to be implemented at the Sadara plant is based on the 60,000 tons per year. The TDI plant is owned and operated by Dow in Camacari, Brazil.

Toluene Di Amine


• Perstorp will be providing its technology for the Formaldehyde plant to the Sadara project. The plant will have an instantaneous design capacity of 130,000 tons per year. It will be fed by Methanol purchased from a third party. The unit will produce a 45% solution of formaldehyde that will be fed to the PMDI plant.

Formalin


• Diisocyanate (PMDI) process for the Sadara project. The plant will have a capacity of 400,000 tons per year and will be fed by the Aniline and Formaldehyde produced in-situ. A Phosgene unit will also be built, CO will be provided from the Syngas unit while Chlorine will be supplied from both the Chlor-Alkali and HCl to Chlorine units.

Polymeric Methylene Diphenyl Diisocyanate


• Dow will provide its Toluene Diisocyanate (TDI) by phosgenation technology to the Sadara project. The plant will have an instantaneous design rate capacity of 208,000 tons per year and will be fed in-situ by the back-integrated TDA plant. The TDI product will be purified and collected for product export.

Toluene Diisocyanate

Corporate awareness. Why not turn the lights on?Sadara portalYammer group

https://catalyst.sadara.com/sites/News/Pages/The-Corporate-Awareness-Series.aspx

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Date post:	06-Aug-2015
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