Sinopec selects Basell’s Lupotech® technology for the LDPE plant in China
Basell announced that China Petroleum & Chemical Corporation (Sinopec) has selected Basell’s Lupotech T technology for a new 250 KT per year LDPE plant to be built at Maoming in Guangdong province, PRC. UHDE GmbH of Dortmund, Germany will be the engineering contractor for the plant, which is scheduled to start up in 2007.
Lupotech T is a high-pressure tubular reactor process for the production of LDPE homopolymers and EVA-copolymers. 26 Lupotech T plants are operating worldwide and another six plants are in construction for a total of 5 million tones per year of licensed capacity.
Comments: Despite its age and the advent of LLDPE and metallocene PE, the use of LDPE continues to increase globally, with higher growth rates in Asia and the Middle East. Unlike other technology licensors, Basell is able to offer a variety of technology platforms for the production of polyolefins including gas, slurry, and high-pressure processes.
As a result, Basell has enjoyed multiple licensing successes in China over the past few years. Basell is also bidding for an LDPE project in the UK. Lupotech T is a high-pressure tubular reactor process for the production of LDPE homopolymers and EVA-copolymers. 26 Lupotech T plants are operating worldwide and another six plants are in construction for a total of 5 million tones per year of licensed capacity.
Sahara Petrochemical & Basell to construct a PP plant in Saudi Arabia
Sahara Petrochemical Company and Basell Holdings Middle East GmbH announced the signing of an agreement to construct a 450 KT per year polypropylene plant and propane dehydrogenation unit at Al-Jubail Industrial City in the Kingdom of Saudi Arabia. The facilities will be operated by a joint venture that Basell and Sahara Petrochemical Company plan to establish in 2005. The start-up of the new plants is targeted for the end of 2007.
The agreement includes a license to utilize Basell’s Spherizone process. The polypropylene from the new plant will be marketed globally by Basell. The propane dehydrogenation unit will be based on the UOP Oleflex process. Saudi Aramco will supply the propane feedstock.
Comments: Basell embarked on developing the Spherizone a few years back with the first commercial plant coming online in Brindisi, Italy in 2002. Earlier this year, Basell licensed a 350 KT Spherizone plant to Mexican firm Indelpro SA de CV. The agreement with Sahara Petrochemical is the second license for the Spherizone process technology platform increasing the aggregate licensed capacity to approximately 1 million tons.
Basell continues to leverage its joint venture-based strategy to increase market penetration. Basell has over a dozen joint ventures concentrated in Asia, Central/South America, and the Middle East. Due to advantaged feedstocks, the Middle East has become of strategic importance to Basell, as well as many other global polyolefins producers. In 2001, Basell (25% stake) and Saudi National Petrochemical Industrialization Company (NPIC – with a 75% stake) established Saudi Polyolefins Company with a capital of $160 million. In 2003, Basell got involved with the Al-Zamil Group to produce 450,000 metric tons per year of polypropylene using the Spheripol process technology. The feedstock for this project is to be sourced from a propane dehydrogenation plant based upon the UOP Oleflex process, a project that is very similar to Sahara Petrochemical. For more information on the Spherizone process, please refer to our New Generation Polyolefins Bimonthly Review (NGP Vol 7 Iss1).
This Basell project probably follows the model of at least two prior propane dehydro projects undertaken in recent years globally by BASF (Basell owner), one in Spain and the other in Southeast Asia.
This is a very large petrochemical-scale project with a propylene base approaching 1 Billion pounds per year. The Al-Jubail location also has other feedstocks available to broaden the portfolio and the UOP dehydro technology is well-proven. Saudi Aramco is the most secure feedstock supplier for the new Basell project and the relationship believes that a propane “collar” (a term for a defined high and low-cost range raw material contract) contract is a more attractive option than selling propane to Asia or Europe in the LPG market. The way this should work is that a floor propane price is established to insulate the project against low propylene values that the industry has seen historically. Even in this era of ultra-high crude prices, it is risky to say we will never see lower prices again. The low floor price of propane ensures the project financing is protected at all times and if (as is currently the case) propylene value increases, the propane supplier shares in some of this upside. This is the “collar” at work, much like the Trinidad natural gas contracts for methanol and ammonia where petrochemical market forces can double or triple the value of the feedstock to the supplier. Based on published similar project economics, the propane floor must be in the range of $1.00-2.00/mm BTUs for a project like this to work.
Sumitomo and Tosoh to reorganize collaboration on linear low-density polyethylene production
Sumitomo Chemical and Tosoh Corporation announced an agreement to reorganize collaboration on linear low-density polyethylene (LLDPE) production through their joint venture, Chiba Polyethylene Co., Ltd.
Effective the end of December 2004, Tosoh will transfer to Sumitomo its equity ownership (25%, 125 million yen) in Chiba Polyethylene Co., Ltd., which will then become a wholly owned subsidiary of Sumitomo. Concurrently, Sumitomo will acquire Tosoh’s product off-take rights from the joint venture, corresponding to its equity shareholding (25% of the annual production capacity of 100 thousand tons). Sumitomo will supply LLDPE of Chiba Polyethylene to Tosoh during an agreed period.
In the future, each Sumitomo and Tosoh will pursue their business development independently. Sumitomo will fully utilize Chiba Polyethylene’s gas phase LLDPE production facilities to manufacture its proprietary, new class of polyethylene (EPPE) and further accelerate its market development of this new product. Tosoh will continue to market LLDPE that it produces at its Yokkaichi Complex.
Comments: Sumitomo (75% stake) and Tosoh (25% stake) established Chiba Polyethylene Co. in 1990 with a capital of 500 million yen. The initial scope of business was the production of linear low-density polyethylene products. Over the years the commodity polyethylene business in Japan and neighboring countries has become increasingly competitive.
In the face of significant ethylene/polyethylene capacity expansions in nearby countries, Japanese producers are finding it hard to stay competitive in the ethylene and derivatives businesses and are looking to further differentiate their products. Some players have even chosen to shift chemical chains (i.e., Mitsui moving away from the ethylene chain to the propylene chain). Tosoh’s transfer of ownership demonstrates its desire to increase emphasis on the specialty sector. Sumitomo also plans to further differentiate itself by producing a new class of polyethylene that they claim provides easy processing characteristics without compromising mechanical/physical properties.
BP’s polyethylene plant at Grangemouth’s production increases
BP introduced higher-rate production runs of linear low-density polyethylene at Grangemouth, Scotland, to meet growing market demand. This has been possible due to the successful introduction of a new best-in-class catalyst, NOVACAT® T, jointly developed between BP and NOVA Chemicals. It is particularly suited for producing BP’s range of linear low-density blown and cast polyethylene film grades.
The Innovene 4 production unit uses proprietary BP Innovene® gas phase technology and has achieved daily and monthly production records throughout this year. Sales in 2004 from this unit are expected to be around 10% up on 2003, with further growth expected in 2005.
Comments: BP and NOVA entered into an agreement in 2001 to license the NOVACAT T technology to Innovene licensees. Shortly thereafter, BP implemented NOVACAT T at the gas-phase facilities in Grangemouth. It is claimed that the catalyst provides stable activity, excellent flowability downstream of the reactor, and the capability to produce enhanced LLDPE products, which has contributed to its success at that location. For NOVA, NOVACAT T provides internal operational benefits and increased revenues from licensing opportunities. For BP, it provides enhanced operability and broadens BP’s Innovene catalyst offerings.
Arkema to increase Orevac® functional polyolefins production capacity in France
Arkema announced its plans to increase the production of Orevac® functional polyolefins at its Mont facility in France. The Orevac® production capacity will be increased by 10,000 MT/year after completion of the extension due in December 2005.
Orevac® functional polyolefins are used as tie-layers for multilayer food packaging as well as in industrial applications (fuel tanks, pipe coating, heating pipes, halogen-free flame-retardant cables, composites, etc.).
Comments: Arkema is a leading producer of petrochemicals, polyolefins, PVC, plasticizers, thermoset resins, polystyrene, and various other chemicals. Arkema produces tie layer resins in France at two major sites including Gonfreville-L’Orcher and Mont, France. Arkema is the largest supplier of tie layer resins in Western Europe. The company sells its tie layer resins under the trade name Orevac®. Arkema manufactures PP, EVA, LLDPE, LDPE, and EVA-based tie layer resins. The company sells tie layers into all tie-layer resin markets in Western Europe. Arkema has excellent relations with the automotive industry in Western Europe.
The total demand for tie layer resins in Europe in 2004 was 59 million pounds. The major markets for tie layer resins include (1) cheese packaging, (2) meat packaging, (3) multilayered bottles, (4) coupling agent for polypropylene, (5) barrier sheets, (6) impact modification of nylon, (7) wood composites, (8) tubing/hoses, and others. Cheese and meat packaging account for the majority of the usage of tie-layer resins. The growth rate for tie layer resins in Europe is over 4% and the company must be expanding capacity to meet this demand and maintain its leading position.
The other major suppliers of tie layer resins in Europe include (1) Arkema (Atofina), (2) Mitsui, (3) DuPont, (4) Rohm & Haas (Morton), (5) DSM (SABIC), and (6) Equistar, with Arkema having the largest market share.
For more information on tie layer resins, please refer to our multiclient study, “Global Tie Layer Resins”. Please contact Chemical Market Resources at 281-333-3313.
Three licensers, Basell, ExxonMobil & Sabtec compete for Huntsman’s LDPE plant
Basell, ExxonMobil Chemical, and Sabtec are the contenders to supply process technology for a previously announced 400,000 MT/year low-density polyethylene (LDPE) plant to be built by Huntsman at Wilton, U.K.
The project forms part of a plan by Huntsman to invest £205 million ($369 million) in the U.K., including £180 million for the Wilton LDPE unit and about £25 million to upgrade the company’s nearby North Tees aromatics complex. Completion is due in third-quarter 2007.
Comments: The planned Huntsman project represents the world’s largest LDPE plant. As of now, Petlin of Malaysia holds the title of the world’s largest single-train high-pressure plant with a nameplate capacity of 255 KT per annum using SABIC’s Clean Tubular Reactor Technology licensed by SABTEC. All of the leading suppliers of high-pressure tubular technology (ExxonMobil, SABTEC, Basell, and Equistar) claim to have technologies that can push the single train capacity envelope to 400+KT. All three technologies are equally qualified as potential candidates.
The major determining factors will have to include any existing/future strategic issues extended over and above the LDPE operations.
GAIL and Iran’s National Petrochemical Company to set up a gas cracker in Iran
Gas Authority of India Limited (GAIL) and the National Petrochemical Company of Iran have announced their plans to set up a gas cracker unit in Iran.
A memorandum of understanding on the proposed project was signed on November 24 in Tehran. Gail may bring in the products for sale in the domestic market, subject to overall market requirements.
The two sides have also agreed to commission the feasibility study, which is expected to be completed by April 2005. Based on the preliminary conceptualization, the gas cracker unit would have a capacity of 800,000 to 1,000,000 tons per annum of ethylene.
Comments: This announcement is consistent with our recent past article in CMR’s publication “New Generation Polyolefins” (NGP), which predicted a higher level of cross-investment between the Middle East and Asia (as opposed to Western investment). Gas Authority of India (GAIL) is mostly owned by the Indian government but is highly profitable. It is aggressively studying or planning olefins expansions in India, including a naphtha cracker in Kasargod and a gas cracker in Assam, as well as the expansion of existing capacity at Auriya, India. GAIL also plans to buy shares in Haldia Petrochemicals. While these plans seem ambitious, GAIL officials have publicly admitted that not all plans may be viable. India has always been considered a primary marketing target for polyolefins manufactured in the Middle East. However, Middle East producers have been limited in their marketing efforts by India’s tariff and non-tariff trade barriers. It is possible that further Indian tariff reductions would occur as Gail begins its Iran operations.
Other Indian producers plan to invest in Iran as well, such as Indian Farmers Fertilizer Cooperative (IFFCO), which plans to build an ammonia export plant. Reliance has also had discussions with the NPC of Iran. However, there are some possible stumbling blocks to Gail’s Iran plans, such as the timing of gas availability and Iran’s unclear methane development plans (especially since the ethane would be sourced from the more expensive non-associated gas).
DuPont to increase Kevlar capacity
DuPont Advanced Fiber Systems (AFS) announced its plans to expand its capacity for Kevlar para-aramid in response to stronger military needs. DuPont expects a global expansion of more than 10 percent, announced in June, to start coming online in late 2005, with completion in 2006.
Between 2000 and 2004, DuPont expanded its Kevlar operations in Spruance, WV, and Maydown, Northern Ireland, three times. The most recent expansion, at Spruance, was completed ahead of schedule early this year. The next expansion will focus on Maydown.
Comments: Kevlar, the p-aramid fiber & the most popular high-strength fiber is in a class by itself. Several materials developed in the 1st twenty years were positioned for the market without major successes. The UHMWPE (Ultrahigh molecular weight high-density polyethylene) from Honeywell –(Allied) is efficient only in composite applications, hence is limited in its applications.
DuPont has done a superb job of making KEVLAR a generic name in defense operations.
Gazprom considers selling stake in Sibur
Russian company Gazprom announced that it received separate, preliminary expressions of interest from BASF, Dow Chemical, and PetroChina in forming an alliance with, or buying a stake in, Gazprom’s Sibur petrochemicals subsidiary.
The company is willing to consider such a deal but that it will not do so until the company has completed a restructuring of Sibur in 2-3 years.
Gazprom approved the first phase of the restructuring plan under which Gazprom will write off the rubles40.1 billion ($1.4 billion) it is owed by Sibur. All of Sibur’s assets will be transferred to a “new publicly run joint-stock” company 100% owned by Gazprom, under the terms of the deal.
Sibur will be responsible for supplying feedstock to the new company and marketing the new company’s products until Sibur has paid off its debts to other creditors, which total about rubles 27.8 billion. Sibur will then cease to exist and all its operations will be transferred to the new company.
Comments: In 2002, Gazprom sold some of its non-profile assets and reduced its cost, and bought back a stake in Sibur. Capitalization of debts in the form of short-term promissory notes permitted Gazprom to further increase its stake in Sibur first from 50.7% to 75.7% in April 2004, and then to 92.3% in June 2004. Gazprom had plans to sell Sibur when it increased its stake.
Sibur is the largest Russian producer of petrochemicals including rubbers, tires, polymers, and liquefied gases. The company’s share in the Russian production of synthetic rubbers, tires, liquefied hydrocarbon gases, and polyethylene averages 47%, 48%, 23%, and 25%, respectively.
GTL Resources to construct methanol complex
GTL Resources has announced its plans to build a large-scale methanol complex in Oman. The company has signed an agreement with Oman Oil Co. (Muscat) and energy marketing group Vitol (Geneva) to build a 3,000 MT/day methanol unit in Salalah, Oman.
Vitol will offtake the plant’s entire output for sale in Asia, Europe, and the Mideast. The plant is expected to cost $350 million-$400 million and use Lurgi’s MegaMethanol technology. Completion is expected in 2008.
GTL has also planned the construction of a methanol plant in Australia with a capacity of 1 million MT/year. Vitol will also sell the entire output from that plant.
Comments: This is a surprising project to some extent because it is only 3,000 MT/day in capacity when the design threshold by Lurgi is up to 6,000 MT/day on other plants. However, it probably just goes to show that any sized project can fly with the right feedstock cost arrangements. If history is repeating itself, a project such as GTL Resources in Oman can expect a long-term natural gas contract (5-10 years or more) at a cost of $.50 – $1.00 per million BTUs. In methanol terms, this will produce methanol at less than .30/gallon ($100/mt) which is somewhat less than half the current market pricing. Methanol prices have hovered near these higher levels for some time due to elevated natural gas costs in developed markets and the outlook most observers agree is for prices to remain high. This means this project should be a strong cash flow generator even at the smaller capacity size proposed.
Mitsui starts an olefins conversion unit in Japan
Mitsui Chemicals started operations at an olefins conversion unit at its Osaka, Japan cracker that will convert ethylene and butenes to propylene using ABB Lummus Global’s metathesis olefins conversion technology (OCT).
The unit will increase propylene production at the site from 280,000 MT/year to 420,000 MT/year. According to ABB, this is the first plant installation in Japan to produce propylene using OCT technology. The project is part of Mitsui’s plan to retrofit its olefins plants in Japan to produce more propylene to keep pace with rapid polypropylene growth.
Comments: Mitsui was the first company to license ABB Lummus’ proprietary olefins conversion technology (OCT) process in Asia. Toyo Engineering was contracted to install the technology to increase propylene capacity at Mitsui’s olefins plant in Osaka, Japan to 420 KT per annum. The OCT technology will change the plant’s propylene-to-ethylene production ratio from 0.6 to more than 1.15. The total investment in the project was $35 million. Earlier this year, Mitsui Chemicals also announced that it would start to place more emphasis on C3-based derivatives to remain competitive in the region. Olefin conversion technology will play an important part in this strategy as propylene remains tight in Asian markets.
Chevron Phillips licenses AROMAX® technology to Compañía Española de Petróleos, S.A.
Chevron Phillips Chemical Company LP (Chevron Phillips Chemical) has entered into a contract to license its AROMAX® process and catalyst technologies for the production of benzene, toluene, and hydrogen to Compañía Espanola de Petróleos, S.A. (CEPSA). The contract also includes Chevron Phillips Chemical’s proprietary metals protection technology for the prevention of carburization.
The AROMAX® technology will be used by CEPSA in their Huelva, Spain aromatics facility as part of a large refinery project that includes an upgrade of existing facilities as well as new construction. The project is expected to start-up in 2006. Chevron Phillips Chemical employees will provide consultation and support during the detailed design and construction of the AROMAX® plant. In addition, Chevron Phillips Chemical representatives are expected to provide training and start-up support.
This agreement reflects a continuation of Chevron Phillips Chemical’s strategy to license selectively its AROMAX® technology. The same technology is presently being utilized at Saudi Chevron Phillips Company, a joint venture between a Chevron Phillips Chemical Company LLC subsidiary and the Saudi Industrial Investment Group in Al Jubail, Saudi Arabia, as well as at Chevron Phillips Chemical’s facility in Pascagoula, Mississippi.
Comments: This plant will provide Europe with a low-cost source of much-needed benzene. A key aspect of the process is the hydrogen it makes available for further chemical production or desulfurization. The carburization technology prevents the reactor metals from degrading without the usual addition of sulfur as in other aromatics processes. Chevron Phillips has had much success with Aromax® and has been building or licensing a new plant almost every two to three years.
Alcan to eliminate 520 jobs in Europe
Alcan announced its plans to close a plastics caps & closures production plant at Cruseilles in France as part of a restructuring in Europe. The closure will account for 94 of the total 520 job losses announced by the company.
In its packaging business, the Garbagnate plant in Italy will also close, resulting in 120 job losses. Downsizing will also take place at plants in Laffon (Italy), Froges (France), and Kolin (Czech Republic). Alcan took over Pechiney of France in 2003, creating a global aluminum and plastics packaging group.
Comments: In 2003, Alcan acquired Pechiney Packaging for about EUR 4.0 billion. The merger between these two companies created the world’s largest aluminum company with about EUR 20.6 billion in sales. After the merger, Alcan is integrating the operations of the two companies and cutting costs by closing the underperforming facilities.
Marcus Oil & Chemicals’ polyethylene wax operations suffer major destruction due to a storage tank explosion
A storage tank explosion at Marcus Oil and Chemicals caused major damage to the plant operations. Investigators’ ruling that the explosion was sparked by a failure in a tank of polyethylene indicates the fire was not intentionally set.
Nine people were injured in multiple explosions, including two firefighters. None of the injuries was life-threatening.
As construction crews worked to scrape hardened polyethylene wax off the plant’s parking lot Saturday, city, state, and federal officials continued to sift through the debris for clues to the fire’s cause. This will be a major disruption for the polyethylene wax operations.
Abbas Hassan, one of the plant’s owners, speculated Saturday that lightning might have hit the plant. “It was an empty tank that exploded. We don’t know anything else at this point,” he said. “Our gut feeling is that lightning struck it. I don’t think it was done on purpose. We hope the insurance recognizes that”.
Comments: In 2003, Dow formed a marketing agreement with Marcus Oil & Chemical Company to supply polyethylene waxes produced by Dow. Dow discontinued the production of Ethylene Styrene Interpolymers in Sarnia in 2003 and then started the PDP plant for polyethylene wax at the same facility.
The demand for polyethylene waxes is growing at about 3.5% per annum in North America. PE waxes are used in several applications such as paints & coatings, hot melt adhesives, printing inks, textiles, plastics & rubber processing, cosmetics, and others. PE waxes mainly compete with paraffin and microcrystalline waxes. They also compete with Fisher-Tropsch and other synthetic waxes in some applications. The major advantages of polyethylene wax over microcrystalline and Fischer-Tropsch waxes are (1) excellent rub resistance, (2) excellent scuff resistance, (3) optimum coefficient of friction, and (4) high melt temperatures. Polyethylene waxes are more insoluble in aromatic solvents than Fischer-Tropsch waxes. They have a higher molecular weight, melting point, and hardness and exhibit much more durability and toughness.
This explosion in a way may speed up the market penetration for metallocene waxes due to the shortage created.
Tarkett agrees to acquire Marley Floors
Tarkett AG worldwide leader in the production and distribution of residential and commercial flooring (mainly vinyl floorings, parquets, and laminates) announced its plans to acquire Marley Floors headquartered in the UK, also a producer of vinyl floor coverings for the commercial sector.
With the acquisition of Marley Floors, Tarkett AG will be in a position to add the high-quality products of Marley Floors to its premium product range in the commercial segment. At the same time, Tarkett AG will be able to continue its growth strategy, thus strengthening its presence in the growing British market for commercial business.
Comments: Tarkett is a leading organization in vinyl flooring worldwide. They along with other major flooring producers like Armstrong have been active in developing polyolefin-based floorings as an alternative to PVC flooring. Vinyl Institute claims Resilient Flooring Industry is strongly committed to the vinyl industry. It is still too early for the flooring industry to ask the same question McDonald’s raised in the late eighties “Are we in the fast food business or the polystyrene foam business?”
BBC’s Bhopal hoax adversely impacts Dow Chemical, Company Stock
In a media hoax coming on the 20th anniversary of the Union Carbide Bhopal disaster, BBC London mistakenly reported that Dow Chemical would take the liability to the tune of $12 billion – sending Dow’s stock into a tailspin.
The incident created an embarrassing situation for the BBC one of the few Global media sources. “There is no basis whatsoever for this report,” said Terri McNeill, spokesperson (this one – we know for sure!) for Dow Chemical Company.
Comments: Union Carbide reached a $470 million settlement with India to cover all claims stemming from the accident in 1989. At the time of the accident Union Carbide owned the majority share and had a controlling interest in UCC India Ltd. After the accident in 1989 and handed the full responsibility back to Union Carbide India Ltd.
The true cause of the disaster is still not determined. The arguments range from (1) employee (UCC India Ltd.) sabotage, (2) gross negligence of safety procedures, (3) lack of maintenance, and (4) lack of safety training.
Whatever the cause may be, the accident involved a release of water into a highly reactive MIC tank, with failure of all of the safety redundancies including, water system, overflow tanks, flares, warning system, etc.,-an extremely low probability high consequence event.
Independent of the disaster, the losses including 20,000 deaths, over 10,000 injuries, unknown long-term impacts, and disruption of a major city of over 200,000 population – were all valued at just $470 million?????,
Exxon Oil spent over a billion dollars and was assessed a fine of $6.5 billion in an accidental grounding of a supertanker by an inebriated captain, a case in which no one died, no one got injured except the fish and the lone Comoran shown on TV over and over again.
Justice! ????
Madam Justice! You ought to color your face black in shame and lower your head – for, Your name is Hypocrite.
You shall seek to punish those who speak their minds – but not this soul, – for, Milady! You know deep in your heart you did wrong! Personal view of Balaji not of CMR Inc.
Lyondell completes Millennium purchase
Lyondell Chemical Company completed the purchase of Millennium Chemicals Inc., creating North America’s third-largest chemical manufacturer.
The combined company, which will operate as Lyondell Chemical Company had consolidated pro forma 2003 revenue of $11.4 billion.
Comments: This signals the completion of the operation that started with the merger of Millennium’s polyolefins operations several years ago.
Dow Chemical to Transfer 70 jobs from West Virginia – exUCC facilities
Dow Chemical Company plans to relocate positions from specialty chemicals, chemicals, and material sciences division from their South Charleston, West Virginia facilities to their headquarters in Midland, MI.
Employees who choose not to relocate could lose their jobs by January 31 – most will be eligible for severance benefits. Carol Dudley, a Dow vice president said in a statement “The desire behind this transition is to retain and build upon valuable capabilities while addressing economic reality”.
The South Charleston Technology Park’s first research laboratory was dedicated in 1949 by the then Union Carbide Chemical Company. The 651-acre facility was acquired by Dow in 2001.
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