ICCA/IEA/DECHEMA Roadmap Catalysis ICCA/IEA/DECHEMA Roadmap Catalysis ICCA/IEA/DECHEMA Roadmap Catalysis ICCA/IEA/DECHEMA Roadmap Catalysis Disclaimer Disclaimer � This presentation contains preliminary results from an ongoing project. g g p j � This data is still subject to revision and correction. � The final results will be published in a joint roadmap. p j p
Petrochemical Industry Energy & GHG Savings via Catalysis –Still a Large Opportunity Opportunity Russel Mills, Dow Chemicals Catalysis Roadmap Partners: Catalysis Roadmap Partners: INTERNATIONAL INTERNATIONAL COUNCIL OF COUNCIL OF CHEMICAL CHEMICAL ASSOCIATIONS ASSOCIATIONS
ICCA/IEA/DECHEMA Roadmap Catalysis ICCA/IEA/DECHEMA Roadmap Catalysis ICCA/IEA/DECHEMA Roadmap Catalysis ICCA/IEA/DECHEMA Roadmap Catalysis High Level Objectives High Level Objectives � Provide credible information on the potential of reducing energy & GHG emissions by applying g gy y pp y g catalysis � Identify key technology breakthroughs, paths to achieve them � Give responsible advice for policy makers on how enable this impact bl hi i
Approach Approach Approach Approach Assumptions: p � Large processes also have the largest saving potential (even if relative improvement potential seems low) � The large number of small/medium-sized processes can be disregarded (even if relative improvement potential seems high)
Approach Approach Approach Approach � Identify ~40 top energy consuming processes y p gy g p � Cut-off at top 10-20 for detailed analysis mption y consum 9 10 9 8 8 7 6 5 4 3 Energy 2 Top 10 Chemicals ‐ Total final BPT energy use (excl. electricity) Top processes accounting for the major (1) Steam cracking (6) Propylene FCC (of 56 processes): 26.0 EJ/yr (2) Ammonia (7) Ethanol ‐ Total final BPT energy use (excl. electricity) share of energy consumption (3) Aromatics extraction (8) Butadiene (C4 sep.) (corrected by 95% coverage): 27.4 EJ/yr 1 (4) Methanol (9) Soda ash (4) Methanol (9) Soda ash ‐ Total final reported energy use Total final reported energy use (5) Butylene (10) Carbon black (excl. electricity): 31.5 EJ/yr ‐ World ‐ wide improvement potentials: 13.0%
Methodology Methodology I Methodology Methodology I Bottom up data compilation by survey Industrial manufacturers survey � Top energy consuming chemical processes � Specific energy consumption and direct GHG emissions � Specific energy consumption and direct GHG emissions (1990 – 2020) � Catalysis impact, future potential, hurdles Catalyst manufacturers survey � Chemical processes, refinery processes, other catalysis areas areas � Catalysis impact, future potential, hurdles Catalyst experts y p � New catalytic processes � Expected breakthroughs, feedstock change � Historical examples Catalysis Roadmap Project l 6
Methodology Methodology II Methodology II Methodology II II Top down data compilation p p SRI Consulting and Chemical Manufacturing Associates Inc. (CMAI) � Production volumes with regional and country distribution P d ti l ith i l d t di t ib ti � Energy Consumptions and allocation to fuels, steam, electricity etc. y � GHG estimates Other sources � Available benchmark studies and technical reports � GHG inventory reports � Special literature � Special literature ⇒ Synthesis of top down with bottom up data Catalysis Roadmap Project l 7
Selection of Subset: Top Energy Selection of Subset: Top Energy Consuming Processes Consuming Processes Consuming Processes Consuming Processes World Total Energy Consumption Chemical & Petrochemical Sector (IEA 2009): 14,9 EJ excl. feedstock (36,2 EJ incl. feedstock) ( ) Preselection: 40 major products manufactured by energy intensive processes (catalytic or with potential to run catalytically) Selection of 18 top products, p p , representing: 9 5 EJ (64% of energy consumption 9,5 EJ (64% of energy consumption of world total chemical production)
Top Top energy Top Top energy energy consuming energy consuming consuming processes consuming processes processes processes � Ammonia � Acrylonitrile � Ethylene � Caprolactam � Propylene � Cumene � Methanol � Methanol � Ethylene Dichloride (EDC) � Ethylene Dichloride (EDC) � BTX � Ethylbenzene � Terephthalic Acid (TPA) � Polyvinyl Chloride (PVC) p ( ) y y ( ) � Polyethylene � Phthalic Anhydride � Styrene � Acetone � Ethylene Oxide � Butadiene � Vinyl Chloride Monomer (VCM) � Acetic Acid � Polypropylene � Polypropylene � Vinyl Acetate (VAM) � Vinyl Acetate (VAM) � Propylene Oxide � Methyl tert-Butyl Ether (MTBE) � Ethylene Glycol � Nitric Acid y y � Phenol � Formaldehyde
Top 18 Top 18 Top 18 chemicals Top 18 chemicals chemicals: ~130 chemicals: 130 : ~130 processes : 130 processes processes processes Acrylonitrile from acetylene Ethylene from ethyl alcohol Ethylene from ethyl alcohol Acrylonitrile from propane Ethylene from gas oil Ethylene from gas oil y p py Acrylonitrile from propylene A l i il f l Ethylene from LPG (propane/butane) h l f ( /b ) Ethylene from LPG (propane/butane) / Ammonia from coal (partial oxidation) Ammonia from coal (partial oxidation) Ethylene from mixed feedstocks Ethylene from mixed feedstocks Ammonia from heavy fuel oil (partial oxidation) Ammonia from heavy fuel oil (partial oxidation) Ethylene from naphtha Ethylene from naphtha Ammonia from naphtha (steam reforming) Ammonia from naphtha (steam reforming) Ethylene from naphtha with BZ Ethylene from naphtha with BZ Ammonia from natural gas (steam reforming) Ammonia from natural gas (steam reforming) Ethylene from propane Ethylene from propane Benzene from catalytic reformate Ethylene from refinery off ‐ gases Ethylene from refinery off ‐ gases Benzene from coal tar Ethylene from selected gas streams from coal ‐ to ‐ oil Benzene from coke oven light oil Ethylene from Superflex technology Benzene from mixed xylenes via toluene disproportionation (MSTDP) Ethylene Glycol from ethylene (ethylene glycol) Benzene from mixed xylenes via toluene disproportionation (MTPX) Benzene from mixed xylenes via toluene disproportionation (MTPX) Ethylene Glycol from ethylene oxide (hydration) Ethylene Glycol from ethylene oxide (hydration) Benzene from propane/butanes (Cyclar) Ethylene Glycol from unspecified raw materials Benzene from pyrolysis gasoline Ethylene Oxide from ethylene (chlorohydrin process) Benzene from toluene dealkylation Ethylene Oxide from ethylene (direct oxidation) Benzene from toluene disproportionation Ethylene Oxide from unspecified raw materials Benzene from toluene/xylenes B f t l / l HDPE G HDPE Gas Phase Ph Benzene from unspecified raw materials HDPE Slurry Caprolactam from cyclohexane (via cyclohexanone) HDPE Solution Caprolactam from cyclohexanone (phenol or cyclohexane ‐ based) HDPE Unidentified Caprolactam from phenol (via cyclohexanone) LDPE Autoclave Caprolactam from toluene LDPE Tubular Cumene from propylene and benzene LLDPE Autoclave Cumene from recovered LLDPE Gas Phase Ethylene from butane Ethylene from butane LLDPE Slurry Ethylene from condensate Ethylene from condensate Ethylene from condensate Ethylene from condensate LLDPE Solution LLDPE Solution Ethylene from deep catalytic cracking of VGO Ethylene from deep catalytic cracking of VGO LLDPE Tubular Ethylene from ethane Ethylene from ethane LLDPE Unidentified Ethylene from ethane/propane Ethylene from ethane/propane LLDPE/HDPE Gas Phase
Boundary Boundary conditions Boundary Boundary conditions conditions conditions � Process system boundaries: � fence to fence (e.g. for EO: ethylene as feedstock, ethylene production not included) � Specific Energy Consumption (SEC) includes: � Specific Energy Consumption (SEC) includes: � direct energy (fuel, steam) � Indirect energy (electricity) gy ( y) � Energy equivalent of feedstock is not included � GHG emissions � Direct process emissions as CO 2 equivalents � Direct utilities emissions (fuel) � � Indirect emissions (electricity) MWh/t > tCO /t* Indirect emissions (electricity) MWh/t -> tCO 2 /t * based on an average energy mix in the U.S (0,584 MT/MWh (electricity) and 0,05598 MT/GJ (heat + fuel))
Energy Energy Energy consumption Energy consumption consumption top 18 consumption top 18 top 18 chemical top 18 chemical chemical products chemical products products products Ammonia 2,75 2,50 2,25 ption [EJ] 2,00 Ethylene 1,75 y Consump 1,50 1,25 ACN ACN Energy Total: 9,5 EJ Propylene 1,00 Caprolactam 5,9 EJ = 62% MeOH 0,75 EG Phenol h l BTX 1,3 EJ = 14% 0,50 PX EO TPA PE VCM 0,25 2,3 EJ = 24% PO Styrene PP C Cumene 0,00 ‐ 50.000 100.000 150.000 200.000 Production volume [kt]
Process related GHG emissions Process related GHG emissions top 18 chemical products top 18 chemical products top 18 chemical products top 18 chemical products 100 600 ill. t] Ethylene Ethylene CO2eq [M 90 Ammonia 500 80 ia GHG as 70 [Mill. t] 400 60 as CO2eq Ammoni MeOH Propylene 50 300 40 GHG a Total 960 Mill t Total: 960 Mill. t TPA TPA 200 Capro ‐ 30 EO 600 Mill. t = 62% PE lactam PX BTX 20 20 PP PP 103 Mill 103 Mill. t = 11% 11% Styrene 100 PO EG VCM 10 257 Mill. t = 27% ACN Phenol Cumene Cumene 0 ‐ ‐ 50.000 100.000 150.000 Production volume[kt]
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