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Industrial Chemistry Class Texas A&M University March 6, 2006
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Where is Celanese? Where is Celanese --- that is, where can you find the chemicals we manufacture? If asked about any of the end uses: Celanese Emulsions coatings in the paints Lightweight Ticona polymers in the Airbus A380 Nutrinova sweetener in the Diet Vanilla Coke TCD Diol adhesive in the DVD Polyvinyl Alcohol in the interior drywall 1,3 Butylene Glycol polyol in the lipstick Polyvinyl alcohol in the adhesive Coatings in the pharmaceuticals Ticona polymers and plastics in the Volkswagen Golf
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Strong leading business
Celanese Today Attractive hybrid business model Sales by Segments* Chemicals % Ticona % Acetate % Performance % Leading global producer position Clear advantage in technology and costs Sales by Regions* North America % Europe % Asia % Opportunities for savings and synergies 2005 sales: $ 6.1 bn 2005 employees: ~9,300 Strong leading business *Percentage of 2005 Celanese projected net sales and Celanese share of equity and cost investments.
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Strategic Growth Region Asia
Tomorro w 33% of Sales in Asia Continue with joint ventures Nanjing Complex New GUR plant Polyplastics Korea Engineering Plastics Nantong Cellulose Fibers Co. Nanjing Acetyl Complex, China Zhuhai and Kunming Fibers Co. KEPCO, Polyplastics subsidiary, Taiwan. Reduce cyclicality; integrated production chain; high growth #1 or #2 position in majority sales with strong focus on further growth in Asia #1 technology; low cost position S&A cost and purchasing savings opportunities; acquisitions’ synergies Stronger supply-demand outlook for longer cycle Polyplastics, Malaysia Celanese Chemicals, Singapore Building our presence in growth regions
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Vision for continued future growth
Automotive, E+E, Medical Devices Ticona Technical Polymers Performance Adhesives, Paints, Coatings, Paper Celanese Emulsions, Polyvinyl Alcohol Acetyls Basic Chemicals Building Blocks For the most part, strengthening core businesses meant making acquisitions to get closer to downstream markets, particularly in Acetyls. Previously, the acetyl chain at Celanese stopped at the level of vinyl acetate monomers. With the acquisition of the Emulsions and PVOH businesses, the acetyls chain comes much closer to end-use applications like paints or adhesives. This reduces Celanese exposure to economic cycles, optimizes supply chain and delivers access to higher margin, specialty markets. Celanese Acetate Cash Drivers Nutrinova Performance Products Markets
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Synthesis Gas in Celanese
Methanol Formaldehyde PE, BG, and TMP Polymers Acetic Anhydride Acetic Acid Synthesis Gas Carbon Monoxide Vinyl Acetate PVOH Emulsions Butyraldehyde Butanol Butyl Acetate Propyl Acetate Propion- aldehyde Propanol Heptanal Heptanoic Acid Nonanal Perlargonic Acid
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Paths to Synthesis Gas Steam Reforming Methanol H2 supply for Alcohols
Partial Oxidation CO supply for Acetic Acid Syngas supply for Aldehyde Coal Gasification
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Syngas from Steam Reforming
CO2 fed to drive water gas shift reaction towards CO Nickel catalyst Desulphurization of Methane Feedstock Endothermic – heat supplied by burning Methane Higher cost source of syngas for Celanese Primarily used for production of Methanol
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Syngas from Steam Reforming
CH4 Steam CO2 Fuel Gas Air Reformer Quench Pot Syngas Gas Purification (amine) Absorber Stripper Conversion dependent on steam:carbon ratio, temperature, and pressure Typical furnace is box-like, numerous catalyst filled tubes Reformer Temperature – ~1450 F Reformer Pressure - ~130 psig Amine used to remove acid gases (primarily CO2)
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Syngas from Partial Oxidation
(Water Gas Shift Reaction) No catalyst Reacted at high temperatures under conditions of insufficient O2 Exothermic – steam generated from heat CO2 can be fed to drive water gas shift reaction towards CO Primary source of syngas for Celanese Used for raw material feed to Acetic Acid and Oxo Units
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Syngas from Partial Oxidation
CH4 O2 Stripper Absorber Scrubber CO2 Syngas Reactor WHB Gas Purification (amine) 1:1 CO:H2 99% CO Syngas Syngas H2 H2 Membrane Coldbox Oxygen/CH4 ratio is important to prevent high temperature or soot conditions Reactor Temperature – ~2500 F Reformer Pressure – 800+ psig Amine used to remove acid gases (primarily carbon monoxide) Membranes or coldbox is used to modify CO/H2 composition
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Syngas from Coal Gasification
No catalyst Exothermic Reaction adjusted through WGS to increase H2 Future source of syngas for Celanese in China
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Coal Gasification Sulfur Sulfur Recovery CO to Coal by Railcar Oxygen (2 100% Trains) Acetic Acid Unit Coal Storage/ Gasification Acid Gas Grinding/Slurry Gas Cooling Cold Box (2 100% Trains) Removal Prep Syngas Steam H2 Sales Slag and Fines Handling Ash Reactor temperatures can operate between 1650 and 2750 F Similar purification steps to remove CO2 and adjust H2 composition Additional process steps required to handle ash and sulfur Additional steps required for handling solid raw material
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Synthesis Gas in Celanese
Methanol Formaldehyde PE, BG, and TMP Polymers Acetic Anhydride Acetic Acid Synthesis Gas Carbon Monoxide Vinyl Acetate PVOH Emulsions Butyraldehyde Butanol Butyl Acetate Propyl Acetate Propion- aldehyde Propanol Heptanal Heptanoic Acid Nonanal Perlargonic Acid
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Reliability Sensitivity
What happens if syngas on-stream reliability (OSR) is poor? Hypothetical Example: Unit producing 2,000 mT/day of acetic acid. Revenue of $100/mT. What is revenue benefit of 98.5% OSR versus 95% OSR?
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Fossil Fuel Pricing Katrina / Rita Sept. 11th
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Natural Gas Pricing $ / MM BTU
South America 2001 Price 2005 Price Chemical Market Associates, Inc., 2005
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What does it take to remain competitive?
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Career Path - Jon Makelki
Process Engineer Bishop Plant 1998 Co-op/Intern Bishop Plant 1996 6 Sigma Black Belt Bishop Plant 2001 Production Engineer Clear Lake Plant 2002 Manufacturing Leader Bay City 2005 Enhancement Engineer Clear Lake, Singapore, China 2003
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Career Path – David Trueba
Process Chemist Carbon Monoxide – Clear Lake 2001 Process Chemist Acetic Acid / Vinyl Acetate – Clear Lake 2001 6 Sigma Black Belt Clear Lake Plant 2004 Performance Enhancement Program (Purchasing) Dallas Global HQ Nov 2004 Global Commodity Leader Raw Materials July 2005
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Conclusion Syngas - basic building block for the industry
Raw materials & end use drive technology application Chemical Market is challenging and mature Drive down costs Improve reliability Drive Innovation
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For more information Visit with your Celanese Key Recruiter
Jeff Kirkpatrick-> Look us up on campus in the Fall Student Engineering Council Career Fair – Sept. 2006 Informational Meeting / On-campus interviews - Oct 2006 25
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