2 Industrial Chemistry Class Texas A&M University March 6, 2006
3 Where is Celanese?Where is Celanese --- that is, where can you find the chemicals we manufacture?If asked about any of the end uses:Celanese Emulsions coatings in the paintsLightweight Ticona polymers in the Airbus A380Nutrinova sweetener in the Diet Vanilla CokeTCD Diol adhesive in the DVDPolyvinyl Alcohol in the interior drywall1,3 Butylene Glycol polyol in the lipstickPolyvinyl alcohol in the adhesiveCoatings in the pharmaceuticalsTicona polymers and plastics in the Volkswagen Golf
4 Strong leading business Celanese TodayAttractive hybrid business modelSales by Segments*Chemicals %Ticona %Acetate %Performance %Leading global producer positionClear advantage in technology and costsSales by Regions*North America %Europe %Asia %Opportunities for savings and synergies2005 sales: $ 6.1 bn2005 employees: ~9,300Strong leading business*Percentage of 2005 Celanese projected net sales and Celanese share of equity and cost investments.
5 Strategic Growth Region Asia Tomorro w33% of Sales in AsiaContinue with joint venturesNanjing ComplexNew GUR plantPolyplasticsKorea Engineering PlasticsNantong Cellulose Fibers Co.Nanjing Acetyl Complex, ChinaZhuhai and Kunming Fibers Co.KEPCO, Polyplastics subsidiary, Taiwan.Reduce cyclicality; integrated production chain; high growth#1 or #2 position in majority sales with strong focus on further growth in Asia#1 technology; low cost positionS&A cost and purchasing savings opportunities; acquisitions’ synergiesStronger supply-demand outlook for longer cyclePolyplastics, MalaysiaCelanese Chemicals, SingaporeBuilding our presence in growth regions
6 Vision for continued future growth Automotive, E+E, Medical DevicesTicona Technical PolymersPerformanceAdhesives, Paints, Coatings, PaperCelanese Emulsions, Polyvinyl AlcoholAcetyls Basic ChemicalsBuilding BlocksFor the most part, strengthening core businesses meant making acquisitions to get closer to downstream markets, particularly in Acetyls. Previously, the acetyl chain at Celanese stopped at the level of vinyl acetate monomers.With the acquisition of the Emulsions and PVOH businesses, the acetyls chain comes much closer to end-use applications like paints or adhesives. This reduces Celanese exposure to economic cycles, optimizes supply chain and delivers access to higher margin, specialty markets.Celanese AcetateCash DriversNutrinovaPerformance ProductsMarkets
7 Synthesis Gas in Celanese MethanolFormaldehydePE, BG, andTMPPolymersAceticAnhydrideAcetic AcidSynthesisGasCarbonMonoxideVinyl AcetatePVOHEmulsionsButyraldehydeButanolButyl AcetatePropyl AcetatePropion-aldehydePropanolHeptanalHeptanoicAcidNonanalPerlargonicAcid
8 Paths to Synthesis Gas Steam Reforming Methanol H2 supply for Alcohols Partial OxidationCO supply for Acetic AcidSyngas supply for AldehydeCoal Gasification
9 Syngas from Steam Reforming CO2 fed to drive water gas shift reaction towards CONickel catalystDesulphurization of Methane FeedstockEndothermic – heat supplied by burning MethaneHigher cost source of syngas for CelanesePrimarily used for production of Methanol
10 Syngas from Steam Reforming CH4SteamCO2Fuel GasAirReformerQuench PotSyngasGas Purification (amine)AbsorberStripperConversion dependent on steam:carbon ratio, temperature, and pressureTypical furnace is box-like, numerous catalyst filled tubesReformer Temperature – ~1450 FReformer Pressure - ~130 psigAmine used to remove acid gases (primarily CO2)
11 Syngas from Partial Oxidation (Water Gas Shift Reaction)No catalystReacted at high temperatures under conditions of insufficient O2Exothermic – steam generated from heatCO2 can be fed to drive water gas shift reaction towards COPrimary source of syngas for CelaneseUsed for raw material feed to Acetic Acid and Oxo Units
12 Syngas from Partial Oxidation CH4O2StripperAbsorberScrubberCO2SyngasReactorWHBGas Purification (amine)1:1 CO:H299% COSyngasSyngasH2H2MembraneColdboxOxygen/CH4 ratio is important to prevent high temperature or soot conditionsReactor Temperature – ~2500 FReformer Pressure – 800+ psigAmine used to remove acid gases (primarily carbon monoxide)Membranes or coldbox is used to modify CO/H2 composition
13 Syngas from Coal Gasification No catalystExothermicReaction adjusted through WGS to increase H2Future source of syngas for Celanese in China
14 Coal GasificationSulfurSulfurRecoveryCO toCoal by RailcarOxygen(2 100% Trains)Acetic Acid UnitCoal Storage/GasificationAcid GasGrinding/SlurryGas CoolingCold Box(2 100% Trains)RemovalPrepSyngasSteamH2 SalesSlag and FinesHandlingAshReactor temperatures can operate between 1650 and 2750 FSimilar purification steps to remove CO2 and adjust H2 compositionAdditional process steps required to handle ash and sulfurAdditional steps required for handling solid raw material
15 Synthesis Gas in Celanese MethanolFormaldehydePE, BG, andTMPPolymersAceticAnhydrideAcetic AcidSynthesisGasCarbonMonoxideVinyl AcetatePVOHEmulsionsButyraldehydeButanolButyl AcetatePropyl AcetatePropion-aldehydePropanolHeptanalHeptanoicAcidNonanalPerlargonicAcid
16 Reliability Sensitivity What happens if syngas on-stream reliability (OSR) is poor?Hypothetical Example: Unit producing 2,000 mT/day of acetic acid. Revenue of $100/mT. What is revenue benefit of 98.5% OSR versus 95% OSR?
20 Career Path - Jon Makelki Process EngineerBishop Plant1998Co-op/InternBishop Plant19966 Sigma Black BeltBishop Plant2001Production EngineerClear Lake Plant2002Manufacturing LeaderBay City2005Enhancement EngineerClear Lake, Singapore, China2003
21 Career Path – David Trueba Process ChemistCarbon Monoxide – Clear Lake2001Process ChemistAcetic Acid / Vinyl Acetate – Clear Lake20016 Sigma Black BeltClear Lake Plant2004Performance Enhancement Program (Purchasing)Dallas Global HQNov 2004Global Commodity LeaderRaw MaterialsJuly 2005
22 Conclusion Syngas - basic building block for the industry Raw materials & end use drive technology applicationChemical Market is challenging and matureDrive down costsImprove reliabilityDrive Innovation
23 For more information Visit with your Celanese Key Recruiter Jeff Kirkpatrick->Look us up on campus in the FallStudent Engineering Council Career Fair – Sept. 2006Informational Meeting / On-campus interviews - Oct 200625
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