► plant conversion for alternative raw materials, or production of new polymers specialities application in fibres/ filament yarns PETvantage® Revamping Conceptions Market Driven Approac
Trang 1EPC PETvantage - Plant Modernization
Revamp | Capacity increase
ENGINEERING & PLANT CONSTRUCTION
®
The EPC Group is certified according to DIN EN ISO 9001:2008
Trang 2► plant conversion for alternative raw materials, or
production of new polymers
specialities application
in fibres/ filament yarns
PETvantage® Revamping Conceptions
Market Driven Approach - Strategic Revamping
Trang 3► Systematic Business Process (1/4)
Technical Feasibility Study
Market Driven Approach - Strategic Analysis
Trang 4► Systematic Business Process (2/4)
Technical Feasibility Study
Market Driven Approach - Strategic Analysis
Trang 5► Systematic Business Process (3/4)
Investment Pay-Off Estimate - All Scenarios (DYNAMIC)
IndustrialEngineering ALL COST in US-Dollar, based on an USD/EUR exchange rate of: 1,260 on November 20, 2008 0,800
2,230 0,900 130
Fix cost USD/MT 43,7 58,5 35,3 58,5 35,3 54,8 35,3 53,1 39,0 36,4 21,3 36,4 19,4 36,4 19,4
Annual fix cost USD 1.986.120 2.250.943 1.851.113 2.250.943 1.851.113 2.108.836 1.851.113 2.043.151 2.043.151 1.909.699 2.187.179 1.909.699 1.995.141 1.909.699 1.995.141
1.307 1.299 991 1.299 991 1.002 991 976 976 991 976 991 976 991 976
130.499.359 1.065
IPA price in USD/kg:
MEG price in USD/kg:
SENSITIVITY ANALYSIS PTA price in USD/kg:
Gross profit margin in USD:
Additional profit margin on add capacity in USD
Total annual production cost (@350 days/year) in USD 123.235.032
Total average production cost
in USD/MT 1.467
25.809.666 26.819.502 14.378.073
114.461.874 1.258
3.486.297 3.955.991
Yearly fix cost savings in USD corresponding to production rate development 135.007 342.799
140.000
Yearly variable production cost savings in USD 1.437.455
Yearly raw material cost savings in USD based on max 150 MT/D capacity
SCENARIO 3A2
116.842
1.066 4.511.972
26.819.502 140.186
5.082.814 1.084
167.926.652 99.317.275
100.442
277.114 284.214
5.285.930
11.002.163 10.651.325
332.224 26.819.502
2.180.622 26.819.502
113.769.586 168.672.644 1.109 1.091 1.071 100.878.890
Technical Feasibility Study
Market Driven Approach - Strategic Analysis
Trang 6► Systematic Business Process (3/4)
Investment Pay-Off Estimate - All Scenarios (DYNAMIC)
2,230 0,900 130
CPU-DMT BPU-DMT CPU-PTA BPU-DMT CPU-PTA BPU-PTA CPU-PTA CBPU CPU-PTA CBPU CPU-PTA CBPU CPU-PTA CBPU CPU-PTA TEX BGC TEX BGC TEX BGC TEX BGC BGC TEX BGC TEX BGC TEX BGC
MT/D 130 110 150 110 150 110 150 110 150 150 300 150 300 150 350
IPA price in USD/kg:
MEG price in USD/kg:
SENSITIVITY ANALYSIS
PTA price in USD/kg:
Gross profit margin in USD:
SCENARIO 3A2 SCENARIO 3A1
SCENARIO 2 SCENARIO 2A SCENARIO 3 SCENARIO DMT SCENARIO 1
BGC = bottle grade chips, TEX = textile grade polymer
Technical Feasibility Study
Market Driven Approach - Strategic Analysis
Trang 7Market Driven Approach - Strategic Business Design
A Technological Feasibility Study defined the appropriate design
…resulting in a business-technological “best-case”conception:
during Implementation of Revamping Scope
Trang 8► tailor-made process plant re-design
► no change of existing reactors
The continuous Polycondensation Capacity Lift
EPC VARIPLANT®
Technology for a successful business future:
Market Driven Approach - PETvantage
Trang 9► Polycondensation Capacity Lift is “Must”
Capacity Lift Needs
Trang 10Utilities/
Energy requirements
Market Driven Approach - PETvantage
Trang 11PET plant capacity lift potentials
Polycondensation Capacity Lift is “Must” to stay competitive through
“Economics-of-Scale”, especially if you take into account that new
production plants with capacities above 1200 t/d will be online in the near future
Before Revamping After Revamping
Trang 12Examples of Significant Achievements Market Driven Approach - PETvantage
Trang 13PET Plant Capacity Lift and Upgrade / Modernisation
Location Volos / Greece
Services of EPC • Feasibility Study
Trang 14► Capacity-, Reliability- & Production Quality Increase
by Modification of a Finisher - … and something more
A very special version of “capacity lift”!
PET Plant Capacity Lift and Upgrade / Modernisation
Trang 15PET Plant Capacity Lift and Upgrade / Modernisation
Location Bobingen / Germany
Services of EPC • Feasibility Study
Trang 16► Capacity Lift and Polymer Specialities Production
PET Plant Capacity Lift and Upgrade / Modernisation
Trang 17Conversion of 4 Existing PET Polycondensation Lines
For PET-chips production from textile fibers to food grade PET-chips (bottle –PET) with simultaneous capacity increase to 1.000 tons per day
Location Yanbu / Saudi Arabia
Services of EPC
• Feasibility Study
• Technological Design
• General Engineering
• Functional Turn-Key Contractor
• Functional Turn-Key, Erection Supervision
• Commissioning Supervision
Client IBN Rushd Saudi Arabia
(a SABIC affiliate)
Realization 2006 - 2009
Trang 18► World-Largest PET Plant Conversion & Debottlenecking
Market Driven Approach - PETvantage
Trang 19► World-Largest PET Plant Conversion & Debottlenecking
Market Driven Approach - PETvantage
Trang 20► World-Largest PET Plant Conversion & Debottlenecking
Market Driven Approach - PETvantage
Trang 21► World-Largest PET Plant Conversion & Debottlenecking
Market Driven Approach - PETvantage
Trang 22Market Driven Approach - PETvantage
350’000 tons/a PET capacity reached
Trang 23► World-Largest PET Plant Conversion & Debottlenecking
per 1 ton of PET, e.g.:
Market Driven Approach - PETvantage
Trang 24► World-Largest PET Plant Conversion & Debottlenecking
some key parameter like:
☺ Acetaldehyde content in BG chips: < 0.3 ppm
☺ Thermal Stress on polymer melt,
Market Driven Approach - PETvantage
Trang 25EPC InsidePET® - Advanced Plant Process Control
Market Driven Approach - PETvantage
Trang 26EPC InsidePET
EXAMPLE (1/3):
Esterification reaction progress control by reactive surface renewal
Automated parameter setting corresponding to plant throughput , including reactive molar ratios correction
COOH end groups setting
for a consistent carboxylic end group level in PET
-COOH end groups control
due to high PTA particle size fluctuation
Reactive molar ratio control
including process glycol components determination confidential
confidential
confidential
confidential confidential confidential
confidential
confidential confidential confidential confidential
confidential
Market Driven Approach - PETvantage
Trang 27Let’s move forward together!
EPC Engineering Consulting GmbH
Mr Karol Kerrane Business Development Manager Contact
Breitscheidstraße 152
07407 Rudolstadt Germany
Phone: +49 3672 302 300 Email: karol.kerrane@epc.com
www.epc.com