Propane Dehydrogenation Technologies November 2016 Report Contents

Propane Dehydrogenation
Technologies
Table of Contents
A Report by NexantThinking™
Process Evaluation/Research Planning (PERP) Program
PERP Report 2016S1 – Published November 2016
www.nexantthinking.com

Section Page

1 Executive Summary ............................................................................................................... 1

1.1 INTRODUCTION ....................................................................................................... 1
1.2 TECHNOLOGY OVERVIEW ..................................................................................... 2
1.3 PATENT ACTIVITY ................................................................................................... 4
1.4 PROCESS ECONOMICS.......................................................................................... 6
1.4.1 Capital Cost .................................................................................................. 6
1.4.2 Regional Cost Competitiveness ................................................................... 6
1.4.3 Regional Investment Attractiveness ............................................................. 7
1.5 GLOBAL PROPYLENE MARKETS .......................................................................... 9
1.5.1 Consumption ................................................................................................ 9
1.5.2 Overall Supply .............................................................................................. 11
1.5.3 PDH Supply .................................................................................................. 11
1.5.4 Supply/Demand and Trade .......................................................................... 12
2 Introduction ............................................................................................................................. 14
2.1 BACKGROUND ......................................................................................................... 14
2.1.1 Ethylene Influence on Propylene ................................................................. 14
2.1.2 Propane and Propylene Price Drivers .......................................................... 15
2.2 PROPYLENE VALUE CHAIN ................................................................................... 17
2.3 TECHNOLOGY OVERVIEW ..................................................................................... 19
2.4 TECHNOLOGY LICENSORS ................................................................................... 20
2.5 BUSINESS DEVELOPMENTS ................................................................................. 21
3 Commercial Technologies ...................................................................................................... 24
3.1 CHEMISTRY ............................................................................................................. 24
3.2 CATALYSTS ............................................................................................................. 25
3.3 PROCESS DESIGN .................................................................................................. 26
3.4 CB&I CATOFIN® PROCESS ..................................................................................... 27
3.4.1 PDH Plant Experience.................................................................................. 27

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3.4.2 Catalyst ........................................................................................................ 28

3.4.3 Process ........................................................................................................ 29
3.4.4 Performance ................................................................................................. 33
3.4.5 Environmental .............................................................................................. 34
3.5 THYSSENKRUPP STAR PROCESS® ...................................................................... 35
3.5.1 PDH Plant Experience.................................................................................. 35
3.5.2 Catalyst ........................................................................................................ 36
3.5.3 Process ........................................................................................................ 36
3.5.4 Performance ................................................................................................. 40
3.6 UOP OLEFLEX™ PROCESS ................................................................................... 41
3.6.1 PDH Plant Experience.................................................................................. 41
3.6.2 Catalyst ........................................................................................................ 42
3.6.3 Process ........................................................................................................ 42
3.6.4 Performance ................................................................................................. 47
4 Developing Technologies ....................................................................................................... 49
4.1 LINDE PDH PROCESS............................................................................................. 49
4.1.1 PDH Plant Experience.................................................................................. 49
4.1.2 Catalyst ........................................................................................................ 49
4.1.3 Process ........................................................................................................ 49
4.2 DOW FLUIDIZED CATALYTIC DEHYDROGENATION ........................................... 53
4.2.1 History and PDH Experience ....................................................................... 53
4.2.2 Catalyst() ....................................................................................................... 54
4.2.3 Process ........................................................................................................ 55
4.2.4 Performance ................................................................................................. 59
4.3 COMPARISON OF PDH TECHNOLOGIES ............................................................. 61
4.3.1 Process Characteristics................................................................................ 61
4.3.2 Major Process Equipment ............................................................................ 62
5 Patent Analysis ....................................................................................................................... 67
5.1 OVERVIEW ............................................................................................................... 67
5.1.1 Types of Patents Considered ....................................................................... 67
5.1.2 Key Patent Categories ................................................................................. 67
5.1.3 Overall Patent Activity by Region ................................................................. 67
5.2 GRANTED PATENTS ............................................................................................... 75
5.2.1 Global ........................................................................................................... 75
5.2.2 North America .............................................................................................. 77
5.2.3 Asia Pacific ................................................................................................... 80
5.2.4 Europe .......................................................................................................... 87
5.2.5 ROW ............................................................................................................. 92
5.3 PATENT APPLICATIONS ......................................................................................... 94
5.3.1 Global ........................................................................................................... 94
5.3.2 North America .............................................................................................. 96
5.3.3 Asia Pacific ................................................................................................... 101

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5.3.4 Europe .......................................................................................................... 115

5.3.5 ROW ............................................................................................................. 119
6 Process Economics ................................................................................................................ 122
6.1 COSTING BASIS ...................................................................................................... 122
6.1.1 Investment Basis .......................................................................................... 122
6.1.2 Pricing Basis ................................................................................................. 122
6.1.3 Cost of Production Basis .............................................................................. 123
6.1.4 PDH Design Basis ........................................................................................ 124
6.2 PROCESS COST COMPETITIVENESS .................................................................. 124
6.2.1 UOP Oleflex ................................................................................................. 124
6.2.2 CB&I CATOFIN ............................................................................................ 134
6.2.3 Dow FCDh .................................................................................................... 143
6.3 CAPITAL COST ........................................................................................................ 152
6.4 REGIONAL COST COMPETITIVENESS ................................................................. 153
6.5 REGIONAL INVESTMENT ATTRACTIVENESS ...................................................... 155
6.5.1 United States ................................................................................................ 155
6.5.2 Western Europe ........................................................................................... 156
6.5.3 Middle East ................................................................................................... 157
6.5.4 China ............................................................................................................ 158
6.5.5 Regional Summary ....................................................................................... 159
6.6 CONCLUSIONS ........................................................................................................ 161
7 Commercial Applications ........................................................................................................ 162
8 Propylene Market Analysis ..................................................................................................... 163
8.1 GLOBAL .................................................................................................................... 163
8.1.1 Consumption ................................................................................................ 163
8.1.2 Overall Supply .............................................................................................. 165
8.1.3 PDH Supply .................................................................................................. 165
8.1.4 Supply/Demand and Trade .......................................................................... 169
8.2 NORTH AMERICA .................................................................................................... 170
8.2.1 Consumption ................................................................................................ 170
8.2.2 Supply .......................................................................................................... 172
8.2.3 Supply/Demand and Trade .......................................................................... 173
8.3 WESTERN EUROPE ................................................................................................ 174
8.3.1 Consumption ................................................................................................ 174
8.3.2 Supply .......................................................................................................... 176
8.3.3 Supply/Demand and Trade .......................................................................... 177
8.4 ASIA PACIFIC ........................................................................................................... 178
8.4.1 Consumption ................................................................................................ 178
8.4.2 Supply .......................................................................................................... 181
8.4.3 Supply/Demand and Trade .......................................................................... 184
9 Glossary ................................................................................................................................. 187
10 References ............................................................................................................................. 189

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Appendix Page

A Definitions of Capital Cost Terms Used in Process Economics ............................................. A-1

B Definitions of Operating Cost Terms Used in Process Economics ........................................ B-1
C PERP Program Title Index (2007 - 2016) .............................................................................. C-1

Figure Page

1.1 Production Profile for Propylene ............................................................................................ 1

1.2 Global PDH Plant Installations ............................................................................................... 2
1.3 Overall Patent Activity 2000-2016 .......................................................................................... 5
1.4 Overall Patent Activity by Region ........................................................................................... 5
1.5 PDH Technologies Capital Cost Comparison ........................................................................ 6
1.6 PDH Technologies Regional Cost of Production ................................................................... 7
1.7 Regional ROCE for PDH Investments ................................................................................... 8
1.8 Global Propylene Demand ..................................................................................................... 9
1.9 Global PDH Cumulative Installed Capacity ............................................................................ 12
1.10 Global Propylene Supply/Demand and Trade........................................................................ 13
2.1 Production Profile for Propylene ............................................................................................ 14
2.2 Propylene Relationship with Ethylene and Propane .............................................................. 15
2.3 China Propane Imports .......................................................................................................... 16
2.4 Routes to Propylene ............................................................................................................... 17
2.5 Propylene Value Chain ........................................................................................................... 18
3.1 Paraffin Dehydrogenation: Thermodynamic Conversion at 1.0 Bara..................................... 25
3.2 CB&I CATOFIN® Process Simplified Process Flow Diagram ............................................... 31
3.3 STAR Process Oxydehydrogenation Thermodynamic Equilibrium........................................ 37
3.4 ThyssenKrupp Industrial Solutions STAR Process® Propane Dehydrogenation Simplified
Flow Diagram ......................................................................................................................... 38
3.5 Oleflex™ Propane Dehydrogenation Simplified Flow Diagram ............................................. 43
3.6 Oleflex™ Catalyst Regeneration Simplified Flow Diagram ................................................... 46
4.1 Linde PDH Process Reaction and Regeneration Section ..................................................... 50
4.2 Linde PDH Process Separation Section ................................................................................ 52
4.3 Dow/Snamprogetti Ethane to Styrene Process ...................................................................... 53
4.4 Dow Fluidized Catalytic Dehydrogenation Process Catalyst ................................................. 54
4.5 Dow FCDh Reactor-Regenerator System .............................................................................. 56
4.6 Dow FCDh Process Simplified Process Flow Diagram .......................................................... 57
5.1 Overall Patent Activity 2000-2016 .......................................................................................... 68
5.2 Overall Patent Activity by Region ........................................................................................... 68
5.3 Overall Patent Activity by Assignee ....................................................................................... 69
5.4 BASF Patent Activity by Type ................................................................................................ 69
5.5 BASF Patent Activity by Category .......................................................................................... 70
5.6 Sinopec Patent Activity by Type ............................................................................................. 70
5.7 Sinopec Patent Activity by Category ...................................................................................... 71

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5.8 Dow Patent Activity by Type................................................................................................... 71

5.9 Dow Patent Activity by Category ............................................................................................ 72
5.10 Lummus Patent Activity by Type ............................................................................................ 72
5.11 Lummus Patent Activity by Category ..................................................................................... 73
5.12 UOP Patent Activity by Type .................................................................................................. 73
5.13 UOP Patent Activity by Category ........................................................................................... 74
5.14 ThyssenKrupp Patent Activity by Type .................................................................................. 74
5.15 ThyssenKrupp Patent Activity by Category ............................................................................ 75
5.16 Breakdown of Global Granted Patents by Country ................................................................ 75
5.17 Breakdown of Global Granted Patents by Assignee .............................................................. 76
5.18 Breakdown of Global Granted Patents by Category .............................................................. 76
5.19 Breakdown of Global Granted Patents by Category .............................................................. 77
5.20 Breakdown of North American Granted Patents by Country ................................................. 77
5.21 Breakdown of North American Granted Patents by Assignee ............................................... 78
5.22 North American Granted Patents by Category....................................................................... 78
5.23 Breakdown of Asia Pacific Granted Patents by Country ........................................................ 81
5.24 Asia Pacific Granted Patents by Assignee ............................................................................. 81
5.25 Asia Pacific Granted Patents by Category ............................................................................. 82
5.26 Breakdown of European Granted Patents by Country ........................................................... 88
5.27 European Granted Patents by Assignee ................................................................................ 88
5.28 European Granted Patents by Category ................................................................................ 89
5.29 Breakdown of ROW Granted Patents by Country .................................................................. 92
5.30 ROW Granted Patents by Assignee ....................................................................................... 92
5.31 European Granted Patents by Category ................................................................................ 93
5.32 Breakdown of Global Patent Applications by Country ........................................................... 94
5.33 Breakdown of Global Patent Applications by Assignee ......................................................... 95
5.34 Breakdown of Global Patent Applications by Category ......................................................... 95
5.35 Breakdown of Global Patent Applications by Category ......................................................... 96
5.36 Breakdown of North American Patent Applications by Country ............................................. 96
5.37 Breakdown of North American Patent Applications by Assignee ........................................... 97
5.38 North American Patent Applications by Category .................................................................. 97
5.39 Breakdown of Asia Pacific Patent Applications by Country ................................................... 101
5.40 Asia Pacific Patent Applications by Assignee ........................................................................ 101
5.41 Asia Pacific Patent Applications by Category ........................................................................ 102
5.42 Breakdown of European Patent Applications by Country ...................................................... 115
5.43 European Patent Applications by Assignee ........................................................................... 115
5.44 European Patent Applications by Category ........................................................................... 116
5.45 Breakdown of ROW Granted Patents by Country .................................................................. 119
5.46 ROW Patent Applications by Assignee .................................................................................. 120
5.47 ROW Patent Applications by Category .................................................................................. 120
6.1 Regional Cost of Production Summary – UOP Oleflex .......................................................... 125
6.2 Regional Cost of Production Summary – CB&I CATOFIN ..................................................... 135

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6.3 Regional Cost of Production Summary – Dow FCDh ............................................................ 144

6.4 PDH Technologies Capital Cost Comparison ........................................................................ 152
6.5 PDH Technologies Regional Cost of Production ................................................................... 154
6.6 United States PDH Capital Intensity and ROCE .................................................................... 156
6.7 Western Europe PDH Capital Intensity and ROCE ............................................................... 157
6.8 Middle East PDH Capital Intensity and ROCE ....................................................................... 158
6.9 China PDH Capital Intensity and ROCE ................................................................................ 159
6.10 Regional ROCE for PDH Investments ................................................................................... 160
8.1 Global Propylene Demand ..................................................................................................... 163
8.2 Global PDH Plant Installations ............................................................................................... 166
8.3 Global PDH Cumulative Installed Capacity ............................................................................ 168
8.4 Global Propylene Supply/Demand and Trade........................................................................ 169
8.5 North American Supply/Demand and Trade .......................................................................... 174
8.6 Western Europe Combined Propylene Supply/Demand and Trade ...................................... 178
8.7 Asia Pacific Combined Propylene Supply/Demand and Trade .............................................. 185
8.8 China Combined Propylene Supply/Demand and Trade ....................................................... 186

Table Page

1.1 Propane Dehydrogenation Technology Licensors ................................................................. 4

1.2 Global Combined Propylene Consumption by Derivative ...................................................... 10
1.3 Global Combined Propylene Consumption by Region ........................................................... 10
1.4 Global Propylene Supply/Demand and Trade........................................................................ 13
2.1 Propane Dehydrogenation Technology Licensors ................................................................. 20
3.1 Propane Dehydrogenation Process Characteristics Summary .............................................. 26
3.2 CATOFIN PDH Overall Material Balance ............................................................................... 33
3.3 CATOFIN PDH Utilities Consumption .................................................................................... 34
3.4 Star Dehydrogenation Process Conditions ............................................................................ 39
3.5 STAR Process Performance Raw Materials and Utilities Consumption ................................ 40
3.6 UOP Oleflex PDH Process Development Timeline ................................................................ 42
3.7 Oleflex PDH Overall Material Balance ................................................................................... 47
3.8 Oleflex PDH Utilities Consumption ......................................................................................... 48
4.1 Dow FCDh Process Overall Material Balance ....................................................................... 60
4.2 Dow FCDh Process Utilities Consumption ............................................................................. 60
4.3 Propane Dehydrogenation Process Characteristics .............................................................. 61
4.4 Propane Dehydrogenation Process Sections ........................................................................ 62
5.1 United States Granted Patents............................................................................................... 79
5.2 Canada Granted Patents ........................................................................................................ 80
5.3 China Granted Patents ........................................................................................................... 82
5.4 South Korea Granted Patents ................................................................................................ 86
5.5 Other Asia Pacific Granted Patents ....................................................................................... 87
5.6 Germany Granted Patents ..................................................................................................... 89
5.7 Russia Granted Patents ......................................................................................................... 90
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5.8 Other European Granted Patents .......................................................................................... 91

5.9 ROW Granted Patents ........................................................................................................... 93
5.10 United States Patent Applications .......................................................................................... 98
5.11 Canada Patent Applications ................................................................................................... 100
5.12 Mexico Patent Applications .................................................................................................... 100
5.13 China Patent Applications ...................................................................................................... 103
5.14 Japan Patent Applications ...................................................................................................... 112
5.15 South Korea Patent Applications ........................................................................................... 113
5.16 Other Asia Pacific Patent Applications ................................................................................... 114
5.17 German Patent Applications................................................................................................... 116
5.18 European Patent Applications ................................................................................................ 117
5.19 ROW Patent Applications ....................................................................................................... 121
6.1 Pricing Basis ........................................................................................................................... 123
6.2 Regional Cost of Production Summary – UOP Oleflex .......................................................... 125
6.3 Cost of Production Estimate: Propylene (USGC) Licensor and Technology: UOP Oleflex .. 127
6.4 Cost of Production Estimate: Propylene (Western Europe) Licensor and Technology:
UOP Oleflex............................................................................................................................ 129
6.5 Cost of Production Estimate: Propylene (Middle East) Licensor and Technology: UOP
Oleflex .................................................................................................................................... 131
6.6 Cost of Production Estimate: Propylene (China) Licensor and Technology: UOP Oleflex .... 133
6.7 Regional Cost of Production Summary – CB&I CATOFIN ..................................................... 134
6.8 Cost of Production Estimate: Propylene (USGC) Licensor and Technology: CB&I
CATOFIN ................................................................................................................................ 136
6.9 Cost of Production Estimate: Propylene (Western Europe) Licensor and Technology:
CB&I CATOFIN ...................................................................................................................... 138
6.10 Cost of Production Estimate: Propylene (Middle East) Licensor and Technology: CB&I
CATOFIN ................................................................................................................................ 140
6.11 Cost of Production Estimate: Propylene (China) Licensor and Technology: CB&I
CATOFIN ................................................................................................................................ 142
6.12 Regional Cost of Production Summary – Dow FCDh ............................................................ 143
6.13 Cost of Production Estimate: Propylene (USGC) Licensor and Technology: Dow FCDh ..... 145
6.14 Cost of Production Estimate: Propylene (Western Europe) Licensor and Technology:
Dow FCDh .............................................................................................................................. 147
6.15 Cost of Production Estimate: Propylene (Middle East) Licensor and Technology: Dow
FCDh ...................................................................................................................................... 149
6.16 Cost of Production Estimate: Propylene (China) Licensor and Technology: Dow FCDh .... 151
8.1 Global Combined Propylene Consumption by Derivative ...................................................... 164
8.2 Global Combined Propylene Consumption by Region ........................................................... 164
8.3 Global PDH Installed Capacity ............................................................................................... 167
8.4 Global Propylene Supply/Demand and Trade........................................................................ 170
8.5 North American Combined Propylene Consumption by Country ........................................... 171
8.6 North American Combined Propylene Consumption by Derivative ....................................... 172
8.7 North American Supply/Demand and Trade .......................................................................... 174

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8.8 Western Europe Combined Propylene Consumption by Derivative ...................................... 176

8.9 Western Europe Combined Propylene Supply/Demand and Trade ...................................... 178
8.10 Asia Pacific Combined Propylene Consumption by Country ................................................. 180
8.11 Asia Pacific Combined Propylene Consumption by Derivative .............................................. 180
8.12 China Combined Propylene Consumption by Derivative ....................................................... 181
8.13 Asia Pacific Combined Propylene Supply/Demand and Trade .............................................. 186
8.14 China Combined Propylene Supply/Demand and Trade ....................................................... 186

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Process Evaluation/Research Planning

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