mr. jon horler - · pdf filea chartered chemical engineer, mr. jon horler has worked for bp...

Mr. Jon Horler

Acetyls Project & Engineering ManagerBP

A Chartered Chemical Engineer, Mr. Jon Horler has worked for BP for 25years and leads a team responsible for the delivery of technology andengineering in support of BP’s proprietary package for the manufactureof Acetic Acid.

Part of his role is also to provide project management during conceptselection and early stage development for licensing opportunitiesworldwide.

Mr. Jon has previously worked on major projects in the UK, China,Taiwan, Malaysia, Korea and India.

Overview of Acetic acid Production

Through Petcoke Gasification

IOCL Petrochemicals Conclave

18th

March 2013

Jon Horler, Projects and Engineering Manager

Acetyls and Aromatics Technology

© 2013 BP Chemicals Limited All rights reserved

Outline

• Overview:

− What is Acetic Acid

− Key Uses of Acetic Acid

− Chemistry

• Feedstock Choices

• Acetic Acid Technology

• Sources of Project Value


3

What is Acetic Acid?

• A very important chemical

• A key raw material for the production of a wide

number of products we use in our everyday

lives

• Do you know that acetic acid in its very dilute

form is vinegar that is consumed or used in the

manufacture of food products?

• Acetic acid is involved in the manufacture of

other items you'll find in your shopping basket,

such as washing powder, drink bottles and food

packaging

With just 1 tonne

of acetic acid our

customers can

make 38,000 jars

of pickles*

*BP Internal Data

© 2013 BP Chemicals Ltd All rights reserved

4

Key uses of Acetic Acid

• Vinyl Acetate Monomer (VAM)

− Paint, adhesives in furniture or floor covering, manufacture

of clothes, shoe soles, juice cartons and cheese packaging,

manufacture of safety glass for car windscreens

• Purified Terephthalic Acid (PTA)

− Plastic containers for beverages, food and electronics,

apparel, home textiles, carpets and industrial fibre products,

audio and video recording tapes, photographic films and

labels

• Acetate Esters (Ethyl Acetate, Butyl Acetate…)

− Solvent in printing inks, laminating adhesive in flexible

packaging and plastic films. Also used as solvent in paint,

varnishes, resin coatings and nail polish remover

• Acetic Anhydride

− More than 75% made into cellulose acetate found in filter

tow, textiles, photographic and x-ray films

− Also used in pharmaceuticals such as aspirin and

paracetamol


Acetic Acid Technology Evolution

CATIVA® gives advantages across all

key project criteria:

• Capital - simplification of flowsheet

results in lower project costs for new

build plants

• Variable Cost - patented catalyst

technology and subsequent reduced

energy requirements result in lower

operating costs

• Cash Cost / Reliability - less

equipment items to maintain mean

lower annual maintenance spends

and less downtime

• Scale - potential to build at scale to

suit market demands improves

capital efficiency

• Fully Built-up Cost - all of the above

have a positive impact on overall

project economics and long term

sustainable operations

Feedstock

changes

Process

changes

Time

Methanol carbonylation Hydrocarbon oxidations

Cost estimates are based on generic models

0

20

40

60

80

100

120

Ethylene Naphtha Rhodium Rhodium / lithium Iridium

Pro

duct

ion c

ost

[in

dex

ed t

o e

thyle

ne

pro

cess

to

tal

cost

= 1

00

]

Cash cost = variable + fixed Capital-related costs=depreciation + return on investment


Methanol Carbonylation:

A C1 route to Acetic Acid

Natural Gas

Coal

Pet Coke

Naphtha

Light HC’s

Heavy HC’s

Biomass

……….

Syngas

(CO + H2)

Purify CO Compress

CO

Pure

CO

Methanol Distribution Methanol

(CH3OH)

Acetic Acid

(CH3COOH)

CO must be generated locally

MeOH purchased as a globally traded commodity

6


Feedstock Selection In India

• Main issues associated with accessing attractive CO economics are:

− High energy costs. Investment in lower capital Nat Gas/Fuel Oil based

Syngas plants (eg SMR/POX) have higher variable costs

− Investment in Coal/Petcoke based Syngas plants (Gasification) delivers

much lower energy / variable cost but carries a much higher capital

cost burden and is dependent on scale and integration opportunity

• For a methanol carbonylation

production, feedstock access

for competitive CO

production cost is key to the

Acetic Acid value chain

Re

lativ

e E

ne

rg

y C

ost

Feedstock Options


8

Ulsan, South Korea

SSBP: AA , 51%

Nanjing, China

Byaco: AA , 50%

Shanghai

Head office

Kertih, Malaysia

BPPA: AA, 70%

Chongqing, China

Yaraco: AA &

Esters , 51%

Kuala Lumpur

Commercial office,

Rest of Asia

Taiwan

FBPC: AA, 50%

Naperville/Cantera

Commercial Office USA

Hull, UK

Europe Commercial Office and

Production

AA and Anhydrides

Texas City

AA

Acetyls sites

Commercial/Sales offices

% BP share of JVs

BP Acetyls – Global Experience


CATIVA® Process Flow Diagram

Vent Gases

To Flare

Acetic Acid

Product

Lights

Removal

Column Heavy Ends Column

Cativa®

SCHEMATIC PROCESS FLOW DIAGRAM

Off-gas Recovery Area

Reactor

(Mixed acid

For disposal)

CO and

methanol

9


Internal Infrastructure

Keys to Project Value

• Build at scale

• Locate near market

• Locate close to

petcoke feedstock

• Integrate common

infrastructure

• Lever the

strengths of both

parties

Value Levers: Project Integration

ASU AA Purification

Petcoke Gasification

External Infrastructure


• Acetic Acid is a petrochemical building block for products associated

with a sophisticate growing modern economy

• BP has developed world leading technology for the manufacture of

acetic acid.

• Feedstock choice is critical

• Integration opportunities help to lever value

Thank You

Summary


mr. jon horler - · pdf filea chartered chemical engineer, mr. jon horler has worked for bp...

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