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EPC PETvantage® - Plant Modernization
Revamp | Capacity increase

ENGINEERING & PLANT CONSTRUCTION


Market Driven Approach - Strategic Revamping
PETvantage® Revamping Conceptions
► plant conversion for alternative raw materials, or

production of new polymers
► increase of capacity / productivity
► conversion from textile- to bottle-PET
► Flexibility through polymers modification for
specialities application
► Flexibility of direct spinning to produce specialities
in fibres/ filament yarns
2

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Market Driven Approach - Strategic Analysis
Technical Feasibility Study

► Systematic Business Process (1/4)
Diagnosis:
Assessment & Analysis of the
Plant to identify the

“key-points” and “limiting
factors”,
Followed by the definition of
technological plant re-vamping
conception for “best-fit”.

4

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Market Driven Approach - Strategic Analysis
Technical Feasibility Study

► Systematic Business Process (2/4)
Pre-Engineering:
Detailed Revamp Project
Technology
(Feasibility Scenarios).

Definition of
Investment Scope, including
Financial Engineering
Models optional.

5

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Market Driven Approach - Strategic Analysis
Technical Feasibility Study

► Systematic Business Process (3/4)
Scenario Study: Confirms Market-Fit & Financial Feasibility
Investment Pay-Off Estimate - All Scenarios (DYNAMIC)
IndustrialEngineering

ALL COST in US-Dollar, based on an USD/EUR exchange rate of:

1,260

SENSITIVITY ANALYSIS

on November 20, 2008

PTA price in USD/kg:

0,800

IPA price in USD/kg:

2,230

MEG price in USD/kg:

0,900

Gross profit margin in USD:
SCENARIO DMT


Description
BGC = bottle grade chips,
TEX = textile grade polymer

SCENARIO 1

SCENARIO 2

SCENARIO 2A

SCENARIO 3

SCENARIO 3A1

SCENARIO 3A2

130
SCEN. 5

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

Variable production cost
USD/MT

65,5

169,3

33,9


169,3

39,6

109,4

37,2

100,0

96,8

27,8

82,0

27,7

76,8

27,7

73,2

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


Raw material consumpt. cost
USD/MT

1.307

Total annual production cost
(@350 days/year) in USD

123.235.032

114.461.874

100.878.890

99.317.275

113.769.586

168.672.644

167.926.652

130.499.359

Total average production cost
in USD/MT

1.467


1.258

1.109

1.091

1.084

1.071

1.066

1.065

1.299

1. Yearly variable production cost savings in USD
2. Yearly fix cost savings in USD

991

1.299

991

1.002

991

976


976

991

976

991

976

991

976

1.437.455

3.486.297

3.955.991

4.511.972

5.082.814

5.285.930

5.383.292

135.007


277.114

342.799

284.214

140.186

332.224

255.802

14.378.073

25.809.666

26.819.502

26.819.502

26.819.502

26.819.502

39.586.365

140.000

100.442


116.842

2.180.622

10.651.325

11.002.163

17.786.622

corresponding to production rate development

3. Yearly raw material cost savings in USD
based on max. 150 MT/D capacity

4. Additional profit margin on add. capacity in USD

6

EPC_PETvantage_Revamping l 2013 l ww.epc.com


Market Driven Approach - Strategic Analysis
Technical Feasibility Study

► Systematic Business Process (3/4)
Scenario Study: Confirms Market-Fit & Financial Feasibility
Investment Pay-Off Estimate - All Scenarios (DYNAMIC)
IndustrialEngineering


ALL COST in US-Dollar, based on an USD/EUR exchange rate of:

1,260

SENSITIVITY ANALYSIS

on November 20, 2008

PTA price in USD/kg:

0,800

IPA price in USD/kg:

2,230

MEG price in USD/kg:

0,900

Gross profit margin in USD:
SCENARIO DMT

Description
BGC = bottle grade chips,
TEX = textile grade polymer

MT/D


7

SCENARIO 1

SCENARIO 2

SCENARIO 2A

SCENARIO 3

SCENARIO 3A1

SCENARIO 3A2

130
SCEN. 5

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

130

110

150

110

150

110

150


110

150

150

300

150

300

150

350

EPC_PETvantage_Revamping l 2013 l ww.epc.com


Market Driven Approach - Strategic Business Design
A Technological Feasibility Study defined the appropriate design
…resulting in a business-technological “best-case”conception:






8


Best Market-Driven Retrofit-Strategy for the Client

Very Competitive Production Cost
High flexibility to adopt Market Changes
Most Feasible Return on Investment ROI Minimum Plant Shut-Down Time
during Implementation of Revamping Scope

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Market Driven Approach - PETvantage
The continuous Polycondensation Capacity Lift
Technology for a successful business future:

► tailor-made

process plant re-design

► no change of existing reactors
► Plant down-time
► ROI

< 4 weeks

less than 2 years!

EPC VARIPLANT®
9


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Market Driven Approach - PETvantage
Capacity Lift Needs

►
%

Polycondensation Capacity Lift is “Must”
100
PET Conversion Cost % vs. Prod. Capacity in T/D
90

►

Economy-ofScale

80

Specific Conversion
Cost Reduction

70

►
60

Increase


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1500

1400

1300

1200

1100

1000

900

800

700

600

500

400

300

200


100

50

10

Overall Efficiency


Market Driven Approach - PETvantage
Production Cost Benefit
Example: 300

Conversion Cost [%]

►

550 T/D (CP + SSP)

100
90
80
70
60
50
40
30
20
10
0


Additives
consumpt.

Utilities/
Energy
requirements
550 T/D

EPC_PETvantage_Revamping l 2013 l ww.epc.com

Specific

Conversion Cost

Fix Cost
(Personnel,
Maintenance)

300 T/D
11

►

Decrease

►

Overall Efficiency


Increase


Market Driven Approach - PETvantage
PET 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

150 t/d

330 t/d

300 t/d

600 t/d

400 t/d

750 t/d

500 t/d

900 t/d

600 t/d


1000 t/d

1200 t/d

2000 t/d

12

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Market Driven Approach - PETvantage

Examples of Significant Achievements


PET Plant Capacity Lift and Upgrade / Modernisation
(to expand the capacity from 160 t/day to 240 t/day)

Location

Volos / Greece

Services of EPC

•
•
•
•

•
•

Client

Artenius Hellas (former VPI)

Realization

2003 - 2005

Feasibility Study
General Engineering
Equipment Supply
Assembling Supervision
Commissioning
Consulting


PET Plant Capacity Lift and Upgrade / Modernisation

► Capacity-, Reliability- & Production Quality Increase

by Modification of a Finisher - … and something more
A very special version of “capacity lift”!

15

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PET Plant Capacity Lift and Upgrade / Modernisation
(To add 140 t/day speciality polyester production (flame retardent PET)

Location

Bobingen / Germany

Services of EPC

•
•
•
•
•
•

Client

Trevira GmbH

Realization

2003 - 2005

Feasibility Study
General Engineering
Equipment Supply
Assembling Supervision
Commissioning Supervision

Consulting


PET Plant Capacity Lift and Upgrade / Modernisation

► Capacity Lift and Polymer Specialities Production

17

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Conversion 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


Market Driven Approach - PETvantage
► World-Largest PET Plant Conversion & Debottlenecking

19

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Market Driven Approach - PETvantage
► World-Largest PET Plant Conversion & Debottlenecking


20

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Market Driven Approach - PETvantage
► World-Largest PET Plant Conversion & Debottlenecking

21

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Market Driven Approach - PETvantage
► World-Largest PET Plant Conversion & Debottlenecking

22

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Market Driven Approach - PETvantage

350’000 tons/a PET capacity reached

23

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Market Driven Approach - PETvantage
► World-Largest PET Plant Conversion & Debottlenecking
EPC PETvantage®,
(1)

Plant Production Cost Improvement via applied PETvantage Technology per 1 ton of PET, e.g.:

☺ Specific total fuel gas consumption: - 15%
☺ Specific total electrical power consumption: - 32%
☺ Specific total cooling energy consumption: - 12%
Overall Approx. Conversion Cost Reduction by: 35%

24

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Market Driven Approach - PETvantage
► World-Largest PET Plant Conversion & Debottlenecking
EPC PETvantage®,
(2)

Plant Production Quality via applied PETvantage Technology, according to
some key parameter like:

☺ Acetaldehyde content in BG chips:
☺ Thermal Stress on polymer melt,

< 0.3 ppm


before: 220 Kelvin-Hours; after: 130 Kelvin-Hours, => - 40%

☺ Very low AA rebuilt rate according to client R&D
☺ and: high quality consistency – thanks to Inside PET !

25

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Market Driven Approach - PETvantage
EPC InsidePET® - Advanced Plant Process Control
• carboxylic end
groups

• intrinsic
viscosity

The Customized Solution for



IV

Consistent
Product Quality and

COOH




Simplified PET

Polycondensation Plant
Operation

TPD
• plant capacity

27

MR
• reactive molar
ratios

EPC_PETvantage_Revamping l 2013 l ww.epc.com