Presentation on theme: "1. Industrial Chemistry Class Texas A&M University March 6, 2006."— Presentation transcript:
Industrial Chemistry Class Texas A&M University March 6, 2006
3 Where is Celanese?
4 Strong leading business *Percentage of 2005 Celanese projected net sales and Celanese share of equity and cost investments. Sales by Segments* Chemicals 66% Ticona 16% Acetate 14% Performance 4% Attractive hybrid business model Leading global producer position Clear advantage in technology and costs Opportunities for savings and synergies Sales by Regions* North America 40% Europe 40% Asia 20% 2005 sales: $ 6.1 bn 2005 employees: ~9,300 Celanese Today
5 Strategic Growth Region Asia Continue with joint ventures Nanjing Complex New GUR plant Building our presence in growth regions KEPCO, Polyplastics subsidiary, Taiwan. Korea Engineering Plastics Zhuhai and Kunming Fibers Co. Polyplastics Polyplastics, Malaysia Celanese Chemicals, Singapore Nantong Cellulose Fibers Co. Nanjing Acetyl Complex, China Tomorro w 33% of Sales in Asia
6 Performance Products Markets Acetyls Basic Chemicals Performance Vision for continued future growth Building Blocks Cash Drivers Celanese Acetate Nutrinova Adhesives, Paints, Coatings, Paper Automotive, E+E, Medical Devices Celanese Emulsions, Polyvinyl Alcohol Ticona Technical Polymers
7 Synthesis Gas Carbon Monoxide MethanolFormaldehyde Polymers Butyraldehyde Propion- aldehyde Butanol Propanol Acetic Acid Vinyl Acetate Acetic Anhydride PVOHEmulsions Heptanal Nonanal Perlargonic Acid Heptanoic Acid PE, BG, and TMP Butyl AcetatePropyl Acetate Synthesis Gas in Celanese
8 Paths to Synthesis Gas Steam Reforming Methanol H 2 supply for Alcohols Partial Oxidation CO supply for Acetic Acid Syngas supply for Aldehyde Coal Gasification CO supply for Acetic Acid
9 Syngas from Steam Reforming CO 2 fed to drive water gas shift reaction towards CO Nickel catalyst Desulphurization of Methane Feedstock Endothermic – heat supplied by burning Methane Higher cost source of syngas for Celanese Primarily used for production of Methanol
1010 Syngas from Steam Reforming Conversion dependent on steam:carbon ratio, temperature, and pressure Typical furnace is box-like, numerous catalyst filled tubes Reformer Temperature – ~1450 F Reformer Pressure - ~130 psig Amine used to remove acid gases (primarily CO 2 ) CH 4 Steam CO 2 Fuel Gas Air Reformer Quench Pot Syngas CO 2 Gas Purification (amine) AbsorberStripper
1 Syngas from Partial Oxidation No catalyst Reacted at high temperatures under conditions of insufficient O 2 Exothermic – steam generated from heat CO2 can be fed to drive water gas shift reaction towards CO Primary source of syngas for Celanese Used for raw material feed to Acetic Acid and Oxo Units (Water Gas Shift Reaction)
1212 Syngas from Partial Oxidation Oxygen/CH 4 ratio is important to prevent high temperature or soot conditions Reactor Temperature – ~2500 F Reformer Pressure – 800+ psig Amine used to remove acid gases (primarily carbon monoxide) Membranes or coldbox is used to modify CO/H2 composition CH 4 O 2 Reactor Scrubber Syngas CO 2 Gas Purification (amine) Absorber Stripper WHB Syngas Membrane 1:1 CO:H 2 H2 Syngas 99% CO H2 Coldbox
1313 Syngas from Coal Gasification No catalyst Exothermic Reaction adjusted through WGS to increase H2 Future source of syngas for Celanese in China
1414 Coal Gasification Coal Storage/ Grinding/Slurry Prep Gasification (2 100% Trains) Slag and Fines Handling Gas Cooling Acid Gas Removal Sulfur Recovery (2 100% Trains) Cold Box Ash Sulfur CO to Acetic Acid Unit H2 Sales Steam OxygenCoal by Railcar Syngas Reactor temperatures can operate between 1650 and 2750 F Similar purification steps to remove CO2 and adjust H2 composition Additional process steps required to handle ash and sulfur Additional steps required for handling solid raw material
1515 Synthesis Gas Carbon Monoxide MethanolFormaldehyde Polymers Butyraldehyde Propion- aldehyde Butanol Propanol Acetic Acid Vinyl Acetate Acetic Anhydride PVOHEmulsions Heptanal Nonanal Perlargonic Acid Heptanoic Acid PE, BG, and TMP Butyl AcetatePropyl Acetate Synthesis Gas in Celanese
1616 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?
1818 Natural Gas Pricing $ / MM BTU $4.5m South America $2.5 / MM BTU $8-14 / MM BTU 2001 Price 2005 Price $1.0 / MM BTU $1.5 / MM BTU $4.0 / MM BTU $5.5 / MM BTU Chemical Market Associates, Inc., 2005
1919 What does it take to remain competitive?
2020 Process Engineer Bishop Plant Sigma Black Belt Bishop Plant 2001 Production Engineer Clear Lake Plant 2002 Enhancement Engineer Clear Lake, Singapore, China 2003 Manufacturing Leader Bay City 2005 Co-op/Intern Bishop Plant 1996 Career Path - Jon Makelki
Sigma Black Belt Clear Lake Plant 2004 Performance Enhancement Program (Purchasing) Dallas Global HQ Nov 2004 Global Commodity Leader Raw Materials July 2005 Process Chemist Carbon Monoxide – Clear Lake 2001 Career Path – David Trueba Process Chemist Acetic Acid / Vinyl Acetate – Clear Lake 2001
2 Conclusion Syngas - basic building block for the industry Raw materials & end use drive technology application Chemical Market is challenging and mature Drive down costs Improve reliability Drive Innovation
2323 For more information Visit with your Celanese Key Recruiter – Jeff Kirkpatrick-> Look us up on campus in the Fall – Student Engineering Council Career Fair – Sept – Informational Meeting / On-campus interviews - Oct 2006