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Delivering 1% Improvements
- 1. Delivering Marginal Gains – How the 1% really matters Boris van Thiel CEO Middle East thyssenkrupp Industrial Solutions
- 3. Agenda • thyssenkrupp @ a glance • Ongoing trends in Middle East • Marginal Gains by - Innovative technologies - Process improvements - Asset Management • Summary
- 4. thyssenkrupp @ a glance Present in nearly 80countries ~17,000 patents in total $45,5bn Sales production sites, offices and service locations all over the world >2,200 employees ~155,000 R&D spending $785mn 2,000 industrial property rights in reporting period
- 5. machines and systems in use worldwide >17,600 of our employees are engineers and technicians Almost 70% chemical installations constructed worldwide Over 2,500 thyssenkrupp Industrial Solutions @ a glance More than years of engineering200 excellence
- 6. thyssenkrupp Industrial Solutions pedigree 20142002 founded in 1859 founded in 1992 founded in 1921 Resource Technologies Process Technologies Industrial Solutions 2015
- 7. Ongoing trends in Middle East region Consolidation Phase Resource Efficiency Expansion of Value Chain Long term Strategic Partnerships Petrochemicals & Refinery Integration Need of Innovative Technology Low Oil Price
- 8. Ongoing trends in Middle East region Monetizing gas, Diversifying local economies and downstream industry as well as job creation C1/C2 based feedstock projects Projects with Specialty/ Differentiated Products Refinery/Petchem Integrated Projects Naphtha Based (non-discounted) projects? Downstream Industry Development? Feedstock drives the Middle East petrochemical industry evolution - not the market Source: IHS Mixed feedstock C1/C2/C3/C4/Light Naphtha based projects
- 9. 0% 20% 40% 60% 80% 100% 0 1 2 3 4 5 6 7 8 9 10 1995 2000 2005 2010 2015 2020 %ofWorldTotal Ethylene Propylene Paraxylene Benzene Methanol Chlorine Middle East Capacity Additions MillionMetricTons Source: IHS Ongoing trends in Middle East region Capacity builds largely driven by gas allocations
- 10. Delivering Marginal Gains Asset Management Innovative Dehydrogenation Technology Process Improvement EPC-S Innovative Urea Technology
- 11. Marginal Gains by Process Improvements
- 12. Key Drivers for Process Improvement Economic Motivation Profit Maximization Competitive Edge Public Requirements Regulatory Social Responsibility
- 14. Evolutionary Process Improvement • Electrolysis: Chlorine and caustic soda production from salt • Power makes up 70-85% of costs in chlorine process • Approx. 7% power saving achieved • Improvement via mechanical design and process control improvements • Widely deployed in Middle East 2,070 2,170 2,130 2,055 2,020 v3 v4 v5plus v5 v6 PowerconsumptioninkWh/tNaOH1) 2008 20111997 20122005
- 15. Revolutionary Process Improvement Production of Propylene Oxide (PO) • Co-product free - traditional routes have co-products and additional market dependency • Environmental friendly hydrogenperoxide based production • Competitive production costs • Licensed to SKC (Korea) and Shenhua (China)
- 16. Marginal gains by Innovative Technology Uhde Fertilizer Technology & Shell Thiogro Technology
- 17. Creating Value in the Fertilizer Market Granular Urea with Elemental Sulphur (ES) brings added value to ALL players • Sulphur to improve yield and quality • Nitrogen, Sulphur applied separately = high cost Farmer: • Low urea prices • Changing markets (US independency) • How to preserve margins? Nitrogen Fertilizer producer: • Abundant Sulphur available: • How to create value out of it? Oil & Gas producer: Granular Urea + elemental Sulphur (ES)
- 18. Granular Urea + ES: Market Situation ~ 10 MMt/a of sulphur needs addition to soil ~ 2 MMt/a covered by other sulphur applications Urea Granulation Middle East Africa Annual Production [MMt/a] 20 13 No of plants 24 14 No of producers 10 8 Elemental Sulphur Annual Production [MMt/a] 12 1.6 No of plants 63 17 No of producers 44 17 Urea is used as carrier for sulphur Source: IHS Chemical Economics Handbook Sulphur 12.5 MMt S/ year world wide deficit by 2015
- 19. Granular Urea + ES: Product Higher nutrient density High agronomic efficiency Balanced nutrients within a single granule Higher nutrient content, higher agronomic efficiency Majority of sulphur particles < 30 µm Uniform distribution of sulphur particles Urea (N) Urea+ES 46% Nitrogen 40% Nitrogen + 13% Sulphur N N N S N NN S S N N NN NN N N N
- 20. Granular Urea + ES: Technology Process condensate Make up Atomising air Air Gran. Additive SC To Storage Air Process Condensate S-Acid Urea solution from evaporat. Fluidisation air Stack Bleed Screen Crusher SC Granulator Scrubber Bucket elevator Final Cooler First Cooler Scrubber Tank Start- up Bin Cooler Scrubber Granulator Safety Screen Fluid bed urea granulation plant adapted Micronized dispersion of elemental sulphur in urea solution (Shell Thiogro) 1 plant 2 products Recycle Vacuum Evaporation Liq. Sulphur ThioAdd Sulphur Dispersion Unit
- 21. Granular Urea + ES: The Value Proposition Farmer needs 5 tons/acre less for same nutrient content Fertilizer required (tons/acre): Urea AS 45.66 Urea ES 40.70 Cost for application (US-Middle East comparison) by adding 6 $USD for sulphur producer gains 92,00 $USD per ton higher revenues! Additional value for urea producer
- 22. Marginal Gains: Dehydrogenation Technology
- 23. STAR process® On-purpose production of propylene growing • Mainly driven by growing demand for Polypropylene • Other products are Propylene Oxide, Cumene, Acrylonitrile, Acrylic Acid, Oxo Alcohols • Demand for propylene outpaces supply from conventional sources (Steam Cracking, Fluid Catalytic Cracking) • Refinery economics & improved fuel efficiency affecting supply from refineries • On-purpose production of propylene required • Share of on-purpose technologies growing from 7% in 2000 and >30% in 2022 Source: IHS Demand Supply Conclusion
- 24. STAR process® - Dehydrogenation Technology Hydrocarbon partial pressure decrease Constant and mild reaction conditions Flexible and safe operation • Advantage in CAPEX & OPEX of raw gas compressor • Less by-products product directly meets the polymer-grade propylene spec. • Lowest catalyst inventory: No moving catalyst or hot switching valves Simple and robust operation less maintenance • Coke directly re-converted into CO/CO2 longer operational cycle between regenerations (usually 7h / 1h ), with high flexibility • Steam also used as purge medium simple stop gas flow in case of any disturbance • Shorter re-start from “hot stand-by“ • Proven annual plant availability of 99%
- 25. Marginal Gains by Asset Management
- 26. Concerns in a running plant HSE Reliability Product Quality Plant Availability Optimized Lifecycle Costs Synergistic Partnerships Statutory Compliances
- 27. Integration of Asset Management Long lasting partnerships basically create value/ Marginal Gains
- 28. Key characteristics of Integrated Asset Management Holistic approach for the whole plant • Solution provider for all disciplines: HSE Operations Mechanical Electrical & Instrumentation • Embedded into client‘s organization and same levels of ”ownership“ for physical assets People Process Technology
- 29. Eliminating the hidden costs Visible Invisible Poor quality Delivery issues Reduced asset life Lost production Reputation damages Safety/ environment risk Services Personnel Materials Energy
- 31. Your contacts Head of Business Development thyssenkrupp Industrial Solutions, KSA KSA KUWAIT BAHRAIN Harald KuttnerAyman El Moghly Head of Sales & Process thyssenkrupp Industrial Solutions, Egypt EGYPT JORDAN LEBANON TUNISIA Vice President Business Development, thyssenkrupp Industrial Solutions, Regionalcluster Gulf States QATAR UAE OMAN + OTHERS Malcolm Cook