Chemtex Group

Chemtex Group
Global Engineering and Project Solutions
July 2010
Topics
1. Chemtex Overview
2. Cellulosic Ethanol Technology
The Chemtex Mission
Chemtex is a global and technology-oriented Engineering Company
that delivers innovative and value-added project solutions for our
clients.
Our mission is to help our customers realize the lowest Total
Installed Costs for their projects. We want to add value through:
– “Smart Engineering” through our understanding of the process;
– Aggressive procurement because we are prepared to take risks
based on an understanding of what we are doing; and,
– Process development/optimization using our in-house R&D
centers.
We have a “can-do” attitude and will strive to meet and exceed
customer expectations. We strive for excellence in our QHSE
performance.
3
Our History
• Founded in 1947 as Rayon Consultants
•
Became Chemtex in 1958
•
Acquired by Mitsubishi Corp in 1989
•
Acquired by M&G Group in 2004
– Privately held company with deep roots in manufacturing
(PET and Acetates)
– 2600 Employees worldwide
– A commitment to R&D (3 Centres) and Process
– USD 2.5 billion annual revenue
– Operations in the USA, Italy, Mexico and Brazil
Today’s Chemtex – a technology oriented global engineering
organization with strong process and R&D competencies, part of a
Group with 70 years of excellence in manufacturing
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Gruppo Mossi & Ghisolfi
1950
1960
1970
1980
1990
2000
2002
2003
2004
2005
2006
2007
M&G was founded in 1953 by
Vittorio Ghisolfi in Tortona, Italy
Packaging
PackagingManufacturing
Manufacturing
Phase
Phase
M&G offered customers packaging
from HDPE and PVC
Chemical
ChemicalSpecialty
Specialty
Manufacturing
ManufacturingPhase
Phase
Group activities were
integrated upstream
in the development
and production of
special resin (PET)
for food packaging Acquisition
applications
of Shell’s
PET
business
Slide 5
PET
PETExpansion
ExpansionPhase
Phase
Acquisition
of Brazilian
controlled
Rhodiaster from
Rhone
Poulenc
Start up of
world’s
largest PET
production
unit at
Altamira
(Mexico)
Acquisition of
the world
class
engineering
group
Chemtex
from
Mitsubishi
Corporation
Start-up of
highest
capacity
single line
PET
production
plant in
Suape, Brazil
A Chemtex
EPC Project
5
M&G – Worldwide Locations
Apple Grove
Resin
Wilmington
Chemtex
Tortona
Head Office
Chemtex
Sharon Center
R&D Centre
Milan
Group Head
Office
Europe Reg.
Office
Verbania
Cellulose Acetate
Rivalta
R&D Ethanol
Rivalta
R&D Packaging
R&D T. R. R.
Houston
North America
Regional Office
Altamira
Resin
Patrica
Resin
Beijing
Chemtex
Poços de Caldas
Resin
Fiber
R&D Centre
Yibin
Cellulose Acetate
Shanghai
Chemtex
Sao Paulo
South America
Regional Office
Indaiatuba
Recycle
Cabo
Fiber
Paulínia
PTA
Pignataro M.
Suape
Film
Resin
(on-stream in late
2006)
Mumbai
Chemtex
Bangalore
Chemtex
6
Market and Technology Focus
Renewables
Fibers & Petrochemicals
Energy & Environmental
7
Providing Project Solutions
Chemtex offers:
•
State-of-the-Art Technologies
•
Technology development with in-house R&D facilities
•
Extensive Technology Transfer Expertise
•
Conceptual and Feasibility Studies
•
Process optimization and de-bottlenecking
•
Front-end and Basic Engineering
•
In-house Detailed Engineering
•
Global Strategic Sourcing
•
EPC capability and experience
•
Plant relocation expertise
•
Financial Engineering capability
We have been working together with clients and technology
partners to deliver successful project solutions worldwide
for more than 50 years
8
Chemtex Offices
Chemtex Italy
Chemtex China
Tortona, Rivalta
Shanghai, Beijing
Chemtex USA
ƒ Annual Turnover:
USD 300 MM
ƒ Employees: 1000
Chemtex India
Wilmington (NC)
Sharon Center (OH)*
Mumbai, Bangalore
* In association with M&G Polymers
9
Our Experience & Our Customers
Highlights:
• Renewables: Bringing proven “bio and alternative” fuel
technologies and application learnings to the marketplace.
• Energy and Environmental: Awarded 7 LNG projects in China in
the last 4 years- bring clean fuel to remote locations.
• Polymers and Fibers: Installing more than 4 million TPA of
polyester capacity in the last 3 years (more than 12 million TPA
total).
• Technology Providers: Helping partners bring their offering to the
international marketplace.
• Alliance Partners: Providing cost-effective engineering services
from Chemtex India to reduce project engineering costs.
10
Selected Recent Projects
11
Technology Transfer Capabilities
• Chemtex offers more than 50 years experience in international
technology transfer and has successfully implemented more than
100 of these projects.
• Chemtex offers expertise in managing and protecting IP with a
carefully planned global sourcing strategy.
• With extensive Contracting and Marketing experience Chemtex
offers support to commercialize technology worldwide.
• Chemtex can support technology provider through all the
technology lifecycle from the idea, to pilot plant, extracting from
the technology the maximum added value.
Idea
Commercialization
Specialty
Differentiated
Commodity
12
Chemtex Technology Relationships
Renewables
Energy &
Environmental
Fibers and
Petrochemicals
Bio - Ethanol from Biomass, Cassava and others
Bio – Ethylene & Bio-Glycols
Bio – Diesel & Glycerine Purification
Biomass Gasification
LNG Plants and Storage Tanks
Combined Heat & Power Generation
Mechanical Biological Treatment for SRF
Biogas recovery solutions
Specialized Waste Water Treatment for heavy
metals, high COD and Oil & Gas process water
Polyester / PET, NGSS, Horizontal SSP
Carbon Fiber Pre-Cursor
Acrylic Fiber
Acetic Anhydride, Cellulose Acetate
13
Supporting Technology Development
Develop Project Economics
Site selection
Technical Support for EIA
Identify Key suppliers (Global)
Partnerships with OEM
Develop Basic Design Package
Design & Supply Commercial Facility
Tech. Support (Construction & S/U)
Pilot Plant
Design Support
Procurement
Data collection with
aim to
commercialize
Commercial
Facility
Identify markets & key Customers
Continue Scale up
IP Protection
Optimize design - Localization
Improve efficiencies
Sustained Revenues (Projects &
Licensing)
IP protection
Extensive experience in 1st generation biofuels technologies
Extensive experience supporting technology licensors and R&D
14
Chemtex R&D
Locations:
• Rivalta, Italy
• Sharon Center, Ohio
Scope of Activities:
• R&D on biofuel and renewable resources
• Operational pilot plant for bio-ethanol
from ligno-cellulosic feedstocks
• Product Applications Support
15
Slide 15
Chemtex Strategic Sourcing
•
Global sourcing and logistics staff of 25 people located across the
globe securing cost and delivery advantages for our clients.
•
Over 50 years experience in global procurement and supply of
equipment and materials.
•
Review key equipment strategies for the projects and identify
potential approaches to lowering overall cost
•
Continuously develop, maintain and audit relationships with key
suppliers to ensure best overall value and service.
•
Utilize the in-house global network to identify best solutions
considering multiple project opportunities, foreign exchange
rates, logistics, duties, vendor capacity, service, etc.).
16
Chemtex EPC Capabilities
• Expertise to develop technology and produce FS, PDPs, FEL and
BE packages.
• Process expertise and experienced execution teams to
implement project solutions.
• In-house high value engineering center in India.
• Global sourcing network.
• International construction management.
• Ability to leverage strategic partnerships throughout the world.
17
Estrella Project, Brazil
Suape Brazil: World’s Largest Polyester 1,500 TPD PET Plant
18
Topics
1. Chemtex Overview
2. Cellulosic Ethanol Technology
–
Biofuels - Are they worth it?
–
Technology, Agronomy and Logistic
–
Pretreatment, Hydrolysis and Fermentation
–
Demonstration Plant - 40ktpa
–
PROESATM Technology Key Features
Biofuels – Are they worth it?
When:
• The CO2 sequestered per hectare by the biomass used to produce
them is high;
• They are economically
US$/barrel;
convenient
even
with
oil
at 50-60
• The production of biomass is eco-sustainable and convenient for
the farmer.
20
The PROESA Objective
Main objective:
Developing a complete crop-to-ethanol value chain through a
conversion technology able to transform selected ligno-cellulosic
material into bio-ethanol in a sustainable way.
Timeframe:
5 years (2007 - 2011)
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Center for Renewable Resources
Fully equipped
analytical and
fermentation
laboratories
Pilot Plant
m2
3000
dedicated to
chemistry and technology
from Renewable Resources
50 staff
dedicated to
R&D activities
22
Topics
1. Chemtex Overview
2. Cellulosic Ethanol Technology
–
Biofuels - Are they worth it?
–
Technology, Agronomy and Logistic
–
Pretreatment, Hydrolysis and Fermentation
–
Demonstration Plant - 40ktpa
–
PROESATM Technology Key Features
Technology & Process Achievements
Biomass
Steam
Main section developed in R&D:
• Experimentation on field and selection of best energy crops.
• Pretreatment developing and testing.
• High solid content enzymatic hydrolysis reactor design.
• Test of enzymes with industrial partner.
• Fermentation test with industrial partner.
• Process Integration and basic Package definition.
Patent Applications Filed: Eleven (11)
24
Agronomy and Logistics
Biomass
Steam
Biomass:
• Experimentation on field done selected Arundo Donax and Fiber
Sorghum as best energy crops candidate for ethanol production;
• Results up to 40 t/ha of dry matter;
• Low input in terms of irrigation and fertilization;
• Developed model for logistic of biomasses.
25
Agronomy and Logistics
• Availability of 60 hectares for R&D related to energy crops
• R&D activities done in order to find the best energy crop for
ethanol production.
26
Why Energy Crops?
•
No food competition.
•
Relatively cheap compared to corn or other cereals.
•
High cellulose and hemi-cellulose content.
•
Can be intensively grown with high yield per hectare.
•
Use of less water and fertilizers respect to cereals.
•
Can be grown on marginal land.
27
Topics
1. Chemtex Overview
2. Cellulosic Ethanol Technology
–
Biofuels - Are they worth it?
–
Technology, Agronomy and Logistic
–
Pretreatment, Hydrolysis and Fermentation
–
Demonstration Plant - 40ktpa
–
PROESATM Technology Key Features
Pre-Treatment Technology
Biomass
Steam
Pretreatment:
• Technical/economical evaluation and comparison of different
existing pretreatments on selected biomass species.
• Lab and/or pilot scale tests on existing pretreatments on
selected biomass species.
• New pretreatment process has been developed.
29
Pre-Treatment
30
Pre-Treatment
9 New Pretreatment Process has been developed at batch scale.
9 Engineering of continuous pretreatment 20 Kg/hr plant has
been completed and started up.
Advantages of Chemtex’s Pre-treatment Process:
• Minimal request of feedstock size reduction.
• High flexibility towards different feedstock.
• Possibility to reduce energy consumption.
• No chemical addition - no special construction
materials required.
• Easy to scale up.
31
Hydrolysis and Fermentation
Biomass
Steam
Enzymatic hydrolysis:
• Defined best enzyme package for selected and pre-treated
biomass.
• Modeling and development of high solid concentration enzymatic
hydrolysis.
• Novel Hydrolysis Set Up.
• Hydrolysis reactor design and scale-up.
• Defined MO for high ethanol conversion.
32
Topics
1. Chemtex Overview
2. Cellulosic Ethanol Technology
–
Biofuels - Are they worth it?
–
Technology, Agronomy and Logistic
–
Pretreatment, Hydrolysis and Fermentation
–
Demonstration Plant - 40ktpa
–
PROESATM Technology Key Features
Demonstration Plant – Key Features
•
Production capacity: 40 ktpa.
•
Production based locally available Arundo Donax and Wheat
Straw.
•
Plant will incorporate all technology features developed during the
R&D project phases.
•
Plant will demonstrate at commercial scale the new pre-treatment
technology (PRIT).
•
Plant will incorporate innovative Hydrolisis and fermentation step
as part of the BIOLYFE FP7 Project.
•
Plant will sell Dry Ethanol to major oil companies.
34
Topics
1. Chemtex Overview
2. Cellulosic Ethanol Technology
–
Biofuels - Are they worth it?
–
Technology, Agronomy and Logistic
–
Pretreatment, Hydrolysis and Fermentation
–
Demonstration Plant - 40ktpa
–
PROESATM Technology Key Features
PROESA™ – Key Features
Unique Pre-Treatment Process producing high quality, low cost sugar
from cellulosic bio-mass
• Flexibility to use different kinds of biomass without hardware
changes.
• High recovery yield for Cellulose and Hemi-cellulose.
• Only steam used - No chemicals.
• Low cost operation - capex and opex.
• Low sugar degradation and low level of contaminants (furfural,
HMF) and possibility to reduce acetic acid concentration via state
of the art technology.
• High quality low cost sugar released.
36
PROESA™ – Key Features
Energy integration through high efficiency burning of Lignin
• Lignin from from the process has
sufficient fuel value to supply all
plant energy requirements.
• The design of each plant includes
a power generation unit.
• Lignin coming from the PROESATM
technology is free of sulfur,
chlorine and ammonia and can
constitute an unique base for
producing chemicals from
biomass.
37
PROESA™ – Summary
2006 - 2008
Scouting, testing and
development of
technology on lab scale
2009
Construction and
tests on continuous
pilot plant
2010
Construction
of Demonstration Plant
40 ktpa
Key Features:
• Capability to use a large variety of biomass as collected
• Unique Pretreatment producing high quality & low cost sugar from
cellulosic biomass
• High efficiency in viscosity reduction enzymatic hydrolysis
• Simultaneous fermentation of C5 and C6 sugars
• Energy integration with high efficiency burning of lignin
38
Why Chemtex
9
A superior technology offering:
• Cost competitiveness – low capex (simplified flow schemes and
no special materials of construction) and opex (no chemicals
required in pre-treatment and energy integration).
• Feedstock flexibility – energy crops or agricultural wastes.
• Uniqueness – IP protection through 11 patent filings.
• Experience – Continuous pilot facility in operation since June
2009 and demonstration plant targeted for start-up in Q4, ‘11.
• Commitment – by Chemtex, M&G and its partners to continuous
development/improvement.
9
Extensive experience with technology transfer.
9
Flexible project solutions based on client needs.
9
Capability to support client also in the development of the
agronomic supply chain.
39
Copyright and Disclaimer
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Chemtex and third party contributors as appropriate. Accordingly, neither the whole nor any part of this document
shall be reproduced in any form nor used in any manner without express prior permission and applicable
acknowledgements. No trademark, copyright or other notice shall be altered or removed from any reproduction.
Disclaimer
This Presentation includes and is based, inter alia, on forward-looking information and statements that are subject to
risks and uncertainties that could cause actual results to differ. These statements and this Presentation are based on
current expectations, estimates and projections about global economic conditions, the economic conditions of the
regions and industries that are major markets for Chemtex and Chemtex’s (including subsidiaries and affiliates) lines of
business. These expectations, estimates and projections are generally identifiable by statements containing words such
as “expects”, “believes”, “estimates” or similar expressions. Important factors that could cause actual results to differ
materially from those expectations include, among others, economic and market conditions in the geographic areas
and industries that are or will be major markets for Chemtex’s businesses, oil prices, market acceptance of new
products and services, changes in governmental regulations, interest rates, fluctuations in currency exchange rates
and such other factors as may be discussed from time to time in the Presentation. Although Chemtex believes that its
expectations and the Presentation are based upon reasonable assumptions, it can give no assurance that those
expectations will be achieved or that the actual results will be as set out in the Presentation. Chemtex is making no
representation or warranty, expressed or implied, as to the accuracy, reliability or completeness of the Presentation,
and neither Chemtex nor any of its directors, officers or employees will have any liability to you or any other persons
resulting from your use.
The Chemtex group consists of legally independent entities, constituting their own separate identities. Chemtex is used
as the common brand or trade mark for most of these entities. In this presentation we may sometimes use “Chemtex
Global”, “Chemtex Group”, “we” or “us” when we refer to Chemtex companies in general or where no useful purpose is
served by identifying any particular Chemtex company.
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