polycarbonate technology opportunities for india · 15th november 2019 epc engineering &...
TRANSCRIPT
Polymers & Fibers
POLYCARBONATE
TECHNOLOGY OPPORTUNITIES
FOR INDIA
INDIAN Petrochem – 2019, Hotel The Lalit, Mumbai
15th November 2019
EPC Engineering & Technologies GmbH, Mr. Karol Kerrane
Polymers & Fibers
TECHNOLOGICAL SOLUTIONS FOR
POLYMER PRODUCTION &
CIRCULAR ECONOMY
GREETINGS FROM GERMANY
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Henkel Henkel – EPC Group
ABOUT US
FAMILY> 300ENGINEERS &
SPECIALISTS
8LOCATIONS IN
GERMANY
140 YEARS OF
EXPERIENCE BUSINESS
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TECHNOLOGY
LICENSING
ENGINEERING
SERVICES
PLANT
CONSTRUCTION
TECHNOLOGY LICENSING
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WE PLAY GLOBAL
> 1.000 PROJECTS
SUCCESSFULLY
DELIVERED
IN > 40COUNTRIES
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• The Only Competition for Innovation
Management
• The Most Important Award for Innovative SMEs
• A Club of Excellence for Germany's Innovation
Elite
The TOP 100 Honors the Most Innovative of Germany's Small
and Medium-Sized Enterprises.
EPC Engineering & Technologies GmbH
has been honored for the second time.
THE TOP 100 HAS BEEN ESTABLISHED FOR 30 YEARS
AND IS:
EPC ENGINEERING & TECHNOLOGIES
RANKS AMONGST THE TOP 100 GERMAN SME‘s
CLIENTS & PARTNERS
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POLYMER AND
CHEMICAL PLANT
TECHNOLOGIES
OUR EXPERTISE
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(PC) POLYCARBONATE / Polycondensation Plants
(PA6) POLYAMIDE 6 / Polymerization Plants
(PET) POLYESTER / Polycondensation Plants
(PAN) POLYACRYLONITRILE / Polymerization Plants
MODIFIED POLYMERS / PET-G, PCT, PBT, PBAT, etc.
RE-VAMPING & OPTIMIZATION
MASTERBATCH PLANTS
PILOT PLANTS
of existing Polymer Plants
for various Polymers
for Polymer Synthesis
(PA 6.6) POLYAMIDE 6.6 / Polymerization Plants
OUR PORTFOLIO IN POLYMERS & FIBERS
(EPS) EXPANDED POLYSTYRENE / Recycling Plants
including optimized Extraction Process
PLANT CONSTRUCTION
PROCESS TECHNOLOGY & GUARANTEES
ENGINEERING PACKAGE
KEY EQUIPMENT DELIVERY
SUPERVISION OF LOCAL ACTIVITES:
Engineering
Installation & Construction
Plant Start-up & Commissioning
FUNCTIONAL
TURNKEY
CONTRACT
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REFERENCE
PROJECTS
SOME EXAMPLES
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CHINA
2011 – 2015
OCC – Ningbo Oceanking Chemical Corp. (Daphoon)
PC POLYCONDENSATION PLANT
EPC´s melt transesterification process for simultaneous
production of different PC grades due to multiple finisher lines
(2 x 50 kta). Patented EPC variPLANT® technology.
LOCATION /
SERVICES BY EPC EPC /
CLIENT /
IMPLEMENTATION /
• Process Technology Package
• Basic Engineering Package
• Key Equipment Delivery
• FAT Quality Control
• Supervision of Installation,
• Supervision of Pre-Commissioning / Commissioning
• Basic recipe package
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Ningbo Zhetie Dafeng - the Complete Production Line
DMC DPC PC PC chips BPA
(production units ) (polycondensation) (final product handling) (unloading & melting)
Ningbo Zhetie Dafeng (Daphoon), the Complete Production Line
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• General Engineering
• General Contractor
• Construction and Assembling Supervision
• Commissioning Supervision
YANBU, SAUDI ARABIA
2007 – 2009
IBN Rushd Saudi Arabia (a SABIC affiliate )
CONVERSION OF 4 EXISTING PET
POLYCONDENSATION SYSTEMS
Conversion from textile fibers to food grade PET production
with a simultaneous capacity increase to 1,000 t/d.
LOCATION /
SERVICES BY EPC
CLIENT /
IMPLEMENTATION /
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• General Engineering
• Delivery of Equipment
• Construction and Assembling Supervision
• Comissioning Supervision
VOLZHSKY, RUSSIA
2007 – 2012
SIBUR I GAZPROM (Chimvolokno)
POLYESTER TIRE CORD PLANTProduction plant for polyester tire cord
LOCATION /
SERVICES BY EPC
CLIENT /
IMPLEMENTATION
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• Basic Engineering
• Detail Engineering
• Equipment Delivery
• Supervision
• Commissioning / Start-Up
• Training
CO2 PURIFICATION AND COMPRESSION
Capacity approx. 15 tons/h carbon dioxide (CO2) high
quality
LOCATION / BAKU, AZERBAIJAN
SERVICES BY EPC /
CLIENT / AzMeCo – Azerbaijan Methanol Company
IMPLEMENTATION / 2013 – 2014
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DAYUSHAN ISLAND, CHINA
2017 – ongoing
Zhejiang Petroleum and Chemical Co., Ltd.
260 KTA POLYCARBONTE PLANT
EPC’s melt trans-esterification process, simultaneous
production of different PC grades due to multiple finisher
lines (EPC Patented technology)
LOCATION /
SERVICES BY EPC EPC
CLIENT /
IMPLEMENTATION /
• Process Technology Package
• Extended PDP Engineering Package
• Key Equipment Delivery
• FAT Quality Control
• Supervision of Installation,
• Supervision of Pre-Commissioning / Commissioning
• Polycarbonate basic recipe package
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PC variPLANT®
Technology Licenses
More than 1 million tons per annum
which is a World Market Share of
> 20%, as per 2018 end
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Sources: GBI Research, IHS markit, EPC
MARKET FORECASTS & GROWTH TRENDS
Year 2000 2010 2020 2025 2028
Rest of World
China
Polycarbonate, Global Demand by Volume (Tons)
2000 – 2028
10 mio -
9 mio -
8 mio -
7 mio -
6 mio -
5 mio -
4 mio -
3 mio -
2 mio -
1 mio -
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Sources: BloombergNews May 2019
PC MARKET EVOLUTION 2018 - 2040
Over 40 Million
new electric vehicles
coming on the road
each year by 2035!
Electrical Vehicles (EVs) Growth Rates until 2040
23PC MARKET IN INDIA 2000 – 2020Polycarbonate Market India, Demand by End-use Segments (Tons)
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EPCvariplant 260 kta
EPCvariplant 180 kta
EPCvariplant 130 kta
PC MARKET IN INDIA 2000 – 2020Polycarbonate Market India, Demand by End-use Segments (Tons)
25PC GRADES AVAILABLE ON MARKET (according to MFR)
75
158
229
588
289
313
210
179
126
74
43
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18
14
3 14
1 1 8 14
3 1 2 5 0 0 0
NU
MB
ER
OF
GR
AD
ES
IN
MA
RK
ET
MFR - MASS FLOW RATE (ASTM D1239 AND ISO 1133)
PC VARIPLANT TECHNOLOGY
>90% of PC Grades
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TRANSESTERIFICATIONPRE-
POLYCONDENSATION I
PRE-
POLYCONDENSATION II
FINAL FINISHING REACTOR
REACTOR 1 REACTOR 2 REACTOR 3
100 %
STAGE 1 STAGE 2
33.3 %
33.3 %
33.3 %
600 - 780 tons of PC per day
Flow diagram for 200 - 260 kta PC Plant with 3 finishing lines (1 – 3L)
EPC VARIPLANT POLYCARBONATE TECHNOLOGY
Plant Efficiency
Process Flexibility
+
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Ningbo Zhetie Dafeng - the Complete Production Line
DMC DPC PC PC chips BPA
(production units ) (polycondensation) (final product handling) (unloading & melting)
Ningbo Zhetie Dafeng (Daphoon), the Complete Production Line
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Integration with up-stream technology providers possible
POLYCARBONATE PRODUCTION PROCESSES
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Phenol
Acetone
Methanol
Carbon
Monoxide
DPC
Production
DMC
Production
HCL
Oxygen
*Typical Consumption Figures for
Ion Exchange Resin Catalyzed Process
Typical Consumption Figures McDermott (LUMMUS) DMC/DPC Technology
BPA Unit
DMC/DPC Unit
Typical Raw Material Consumption for 130 KTPA PC Production
CumeneBenzolMethyl
Cyclohexane ToluolNaphta
Propylene
LUMMUS
PCSpent Phenol
Spent DPC
BPA
H2O
CO2
H2O
Methanol+DMC
DPC
Anisole
Polycarbonate Production Unit
EPC VARIPLANT® Technology
130-260 KTA
Polycarbonate Chips
LUMMUS
BPA
Light and Heavy Bleeds Off-gas
30CIRCULAR ECONOMY
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Circular
Economy
MACRO & MICRO CIRCULARITY
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Management & Optimization
of
Effluent and Waste Streams
CIRCULAR ECONOMY
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Raw
Mate
rials
Utility Supply
(Steam, Electricity, etc.)
Gaseous
Solid
Liq
uidWaste:
Treatment
Process Production Plant End Product
Gaseous
Solid
Liquid
Burner /
Combustion
Emissions & Effluents
Waste Streams
CO2
Recovery
Possible
Thermal Energy
Recovery
Battery Limit (BL)
CIRCULAR ECONOMYThe Optimization and Re-use of Waste Streams: Thermal Energy Savings ≥15% Sustainability
EPC VARIPLANT POLYCARBONATE TECHNOLOGY
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• Basic Engineering
• Detail Engineering
• Equipment Delivery
• Supervision
• Commissioning / Start-Up
• Training
PLANT FOR CO2 PURIFICATION AND
COMPRESSION
Capacity approx. 15 tons/h carbon dioxide
(CO2) high quality
LOCATION / BAKU, AZERBAIJAN
SERVICES BY EPC /
CLIENT / AzMeCo – Azerbaijan Methanol Company
IMPLEMENTATION / 2013 – 2014
Reference
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CO2 Recovery
This System can recover more then 90 % of the CO2 emissions from the PC plant off-gas (OG).
The CO2 purity will be more than 97%.
(possible max. purity 99.5%, if required)
Another advantage: optional use of the condensed water from the washer as demin water (DW).
HTM
Plant CO2
CO2
Recovery
PlantOG
OG
D
W
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CO2 Liquefaction
HTM Plant CO2 (g)
EnergieCO2
Recovery
Plant
OG
OG
Liquefaction CO2 (l)
D
W
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Possibilities CO2
Dry ice production
A PC Plant with 180 kta can produce 1.3 t/h
CO2 (s).
The CO2 (s) can be used to climatize processes in
laboratories.
The CO2 (s) can be used in the beverage industry.
The CO2 (s) can be used in the food industry (cold
chain).
1
2
3
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CO2-RECOVERY PLANT – CTK 600
For dry ice production capacity of 2 x 600 kg/h
LOCATION / AUSTRALIA
CLIENT / COMTECSWISS
IMPLEMENTATION / 2018 (under construction)
SERVICES BY CRYOTEC /
• Consulting
• Pre-Engineering
• Basic / Detail Engineering
• Plant Delivery
• Project Management
• Operation Start-Up
• After Sales Services
Reference
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Application for CO2
1. Industrial applications – e.g. MEG
2. Methanol etc.
3. Dry Ice
4. Medicine and Pharma industry
5. Food industry
6. Agriculture
1 2
3 4
5 6
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Integration with up-stream technology providers possible
POLYCARBONATE PRODUCTION PROCESSES
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EPC Supervision Service / Technical Assistance
EPC variPLANT®
Process Training
Plant SafetyTraining
Plant Operation Training
Plant Commissioning
Plant Pre-Commissioning
Plant Erection
EPC VARIPLANT POLYCARBONATE TECHNOLOGY
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No restrictive license terms
No ongoing license fees
Produce the PC Grades you want,
Produce the PC Quantities you want,
Sell into the Global Market where you want
& when you want.
A one-off License Fee for EPC know-how
and technology license
Licensing Advantages
EPC VARIPLANT POLYCARBONATE TECHNOLOGY
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TYPICAL CONTRACT STRUCTURE
1) Engineering Contract
▪ Extended PDP Engineering
incl. Application Software for DCS Process
plant control & SIS fail-safe software
▪ Technical Service
▪ License Fee
2) Equipment Delivery Contract
▪ Proprietary / key equipment
▪ Spare parts package
EPC VARIPLANT POLYCARBONATE TECHNOLOGY
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Leading German Polycarbonate Technology Provider
EPC VARIPLANT POLYCARBONATE TECHNOLOGY
Karol Kerrane & Michael Streng
CONTACT US
EPC Group is certified per DIN EN ISO 9001
EPC Engineering & Technologies GmbH
Dr.-Bonnet-Weg 1
99310 Arnstadt
Germany
Karol KerraneBusiness Development Director
T +49 3628 / 660 48 2900
W www.epc.com
THANK YOU VERY MUCH FOR YOUR ATTENTION