Terephthalic Acid

PERP 09/10-6

May 2011

Aline Bastidon

CHEMSYSTEMS
PERP PROGRAM

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The ChemSystems Process Evaluation/Research Planning (PERP) program is recognized globally as

the industry standard source for information relevant to the chemical process and refining industries.
PERP reports are available as a subscription program or on a report by report basis.

Nexant, Inc. (www.nexant.com) is a leading management consultancy to the global energy, chemical, and related industries. For over 38 years,
ChemSystems has helped clients increase business value through assistance in all aspects of business strategy, including business intelligence, project
feasibility and implementation, operational improvement, portfolio planning, and growth through M&A activities. Nexant has its main offices in
San Francisco (California), White Plains (New York), and London (UK), and satellite offices worldwide.
For further information about these reports, please contact the following:
London, Dr. Alexander Coker, Manager PERP Program, phone: + 44-(20)-70950-1570, e-mail: acoker@nexant.com.
New York, Dr. Jeffrey S. Plotkin, Vice President, phone: + 1-914-609-0315, e-mail: jplotkin@nexant.com;
or Heidi Junker Coleman, Multi-client Programs Administrator, phone: + 1-914-609-0381, e-mail: hcoleman@nexant.com.
Website: www.chemsystems.com
Copyright © by Nexant Inc. 2011. All Rights Reserved.
Contents
Section Page

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

1.1 TECHNOLOGY ............................................................................................ 2
1.1.1 Purified Terephthalic Acid ................................................................. 2
1.1.2 Medium Quality Terephthalic Acid ................................................... 5
1.1.3 Technology Developments ................................................................ 5
1.2 ECONOMICS ................................................................................................ 9
1.2.1 Process Comparison ........................................................................... 9
1.2.3 Regional Comparison......................................................................... 12
1.2.4 Conclusion ......................................................................................... 15
1.3 COMMERCIAL ............................................................................................ 16
1.3.1 Applications ....................................................................................... 16
1.3.2 Markets .............................................................................................. 17
2 Introduction .............................................................................................................. 21
2.1 GENERAL ..................................................................................................... 21
2.2 OVERVIEW OF TEREPHTHALIC ACID TECHNOLOGY
LICENSING .................................................................................................. 21
3 Purified Terephthalic Acid (PTA) Technology ..................................................... 23
3.1 CHEMISTRY ................................................................................................ 23
3.2 CONVENTIONAL PROCESS ...................................................................... 24
3.2.1 CTA Production Process .................................................................... 29
3.2.2 PTA Production Process .................................................................... 32
3.3 DAVY PROCESS TECHNOLOGY/DOW (DPT/DOW) ............................. 35
3.3.1 Chemistry ........................................................................................... 36
3.3.2 Process Description ............................................................................ 36
3.3.3 Process Features ................................................................................. 43
3.4 INVISTA........................................................................................................ 44
3.4.1 CTA Production Process .................................................................... 44
3.4.2 PTA Production Process .................................................................... 47
3.4.3 Process Features ................................................................................. 51
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 3.5 BP (AMOCO) ................................................................................................ 51
3.5.1 Process Description ............................................................................ 52
3.5.2 Process Features ................................................................................. 56
3.6 GTC TECHNOLOGY ................................................................................... 57
3.6.1 Process Description ............................................................................ 57
3.6.2 Process Performances ........................................................................ 63
3.6.3 Process Features ................................................................................. 65
4 Medium Quality Terephthalic Acid (MTA) .......................................................... 66
4.1 INTRODUCTION ......................................................................................... 66
4.2 EASTMAN/LURGI EPTA PROCESS ......................................................... 67
4.2.1 Process Description ............................................................................ 67
4.2.2 Claimed Advantages .......................................................................... 76
4.3 MITSUBISHI CHEMICAL QTA PROCESS ............................................... 77
4.3.1 Overview ............................................................................................ 77
4.3.2 Process Description ............................................................................ 78
4.3.3 Specification ...................................................................................... 79
4.3.4 Experience.......................................................................................... 79
4.4 COMPARISON OF MTA AND PTA ........................................................... 80
4.4.1 Quality and Potential Color Formation .............................................. 80
4.4.2 Application Comments ...................................................................... 82
4.5 CONCLUSIONS............................................................................................ 84
4.5.1 Usage and Cost Issues ........................................................................ 84
4.5.2 Market Issues ..................................................................................... 84
5 Patent Review ........................................................................................................... 86
5.1 DOW .............................................................................................................. 86
5.1.1 Oxidation Reactor Design Improvement ........................................... 86
5.1.2 Oxidation Catalyst Recovery ............................................................. 88
5.2 BP ................................................................................................................... 90
5.2.1 Catalyst Innovations........................................................................... 90
5.2.2 Common Solvent for Oxidation and Hydrogenation ......................... 91
5.3 MITSUBISHI GAS CHEMICAL .................................................................. 92

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 5.4 MITSUBISHI CHEMICAL CORPORATION ............................................. 93
5.4.1 Oxidation Intermediates Recovery .................................................... 93
5.4.2 Solid/Liquid Separation System ........................................................ 95
5.4.3 Improved Solvent Recovery with Membrane .................................... 95
5.5 MECHEMA CHEMICALS INTERNATIONAL.......................................... 96
5.6 SAUDI BASIC INDUSTRIES CORPORATION ......................................... 98
5.7 HRONEC ET AL. .......................................................................................... 99
5.8 EASTMAN CHEMICAL .............................................................................. 99
5.8.1 Improved Oxidation Bubble Reactor ................................................. 99
5.8.2 Improved Energy and Solvent Recovery ........................................... 100
5.9 SAM NAM PETROCHEMICALS ................................................................ 102
5.10 WHAT IS THE NEXT STEP FOR PTA? ..................................................... 105
5.10.1 Process Intensification ....................................................................... 105
5.10.2 Supercritical Route to PTA ................................................................ 108
5.10.3 Alternative Feedstock - Green Route to PTA .................................... 109
6 Economics ................................................................................................................. 113
6.1 BASIS ............................................................................................................ 113
6.1.1 Pricing Basis ...................................................................................... 113
6.1.2 Investment Basis ................................................................................ 113
6.1.3 Cost of Production Basis .................................................................... 114
6.2 PROCESS COMPETITIVENESS ................................................................. 115
6.2.1 Conventional PTA Production ........................................................... 116
6.2.2 COMPRESS™PTA Production......................................................... 118
6.2.3 INVISTA PTA Production ................................................................ 120
6.2.4 BP PTA Production............................................................................ 124
6.2.5 GTC Technology PTA Production .................................................... 126
6.2.6 Eastman/Lurgi MTA Production ....................................................... 128
6.2.7 Conclusion ......................................................................................... 133
6.3 REGIONAL COMPETITIVENESS .............................................................. 133
6.4 CONCLUSION .............................................................................................. 143

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7 Commercial Applications ........................................................................................ 145
7.1 FIBER ............................................................................................................ 145
7.1.1 Textile Fibers ..................................................................................... 145
7.1.2 Fiberfill .............................................................................................. 146
7.1.3 Non-woven Fabrics ............................................................................ 146
7.1.4 Carpet Facing ..................................................................................... 146
7.1.5 Industrial Fibers ................................................................................. 146
7.2 CONTAINER ................................................................................................ 146
8 Regional Market Review ......................................................................................... 148
8.1 GLOBAL OVERVIEW ................................................................................. 148
8.1.1 Consumption ...................................................................................... 148
8.1.2 Supply ................................................................................................ 150
8.2 NORTH AMERICA ...................................................................................... 152
8.2.1 Overview ............................................................................................ 152
8.2.2 Consumption ...................................................................................... 152
8.2.3 Supply ................................................................................................ 154
8.2.4 Supply, Demand, and Trade............................................................... 155
8.3 WESTERN EUROPE .................................................................................... 156
8.3.1 Consumption ...................................................................................... 156
8.3.2 Supply ................................................................................................ 157
8.3.3 Supply, Demand, and Trade............................................................... 159
8.4 ASIA PACIFIC .............................................................................................. 159
8.4.1 Overview ............................................................................................ 159
8.4.2 Consumption ...................................................................................... 160
8.4.3 Supply ................................................................................................ 162
8.4.4 Supply, Demand, and Trade............................................................... 167
9 Glossary .................................................................................................................... 168
10 References ................................................................................................................. 170
Appendix Page

A Nexant's ChemSystems Capital Cost Estimates.................................................... A-1

B PERP Program Title Index (2000/2001 - 2009/2010) ............................................ B-1

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Figure Page

1.1 Terephthalic Acid Process Comparison, USGC – 2010 Q2 ...................................... 12

1.2 Forthcoming Plants Competitiveness, 2010-2015 ..................................................... 14
1.3 Global PTA Consumption.......................................................................................... 18
1.4 Global PTA Capacity Additions ................................................................................ 19
1.5 Global PTA Capacity ................................................................................................. 20
3.1 Crude Terephthalic Acid Process (Block Flow Diagram) ........................................ 25
3.2 Purified Terephthalic Acid Process (Block Flow Diagram) ...................................... 26
3.3 Crude Terephthalic Acid Process Flow Diagram ..................................................... 30
3.4 Purified Terephthalic Acid Process Flow Diagram .................................................. 34
3.5 COMPRESS™ PTA - CTA Flow Diagram ............................................................... 38
3.6 COMPRESS™ PTA - Purification Process Flow Diagram ...................................... 41
3.7 INVISTA CTA Process Flow Diagram .................................................................... 46
3.8 INVISTA Pure Terephthalic Acid Process Flow Diagram ....................................... 49
3.9 BP Amoco Terephthalic Acid Process Flow Diagram ............................................ 53
3.10 GTC Technology Basic Process Diagram ................................................................. 58
3.11 GTC Technology Flow Diagram ............................................................................... 59
3.12 Solubility Curve in NMP ........................................................................................... 63
3.13 Solubility Curve in Methanol..................................................................................... 63
3.14 Water Ratio Influence on Conversion........................................................................ 64
3.15 Hydrogen Peroxide Ratio Influence on Conversion .................................................. 64
4.1 Eastman/Lurgi EPTA Block Flow Diagram ............................................................. 68
4.2 EPTA Technology Process Flow Diagram ............................................................... 69
5.1 Dow’s Liquid Gas Phase Improved Reactor System ................................................. 87
5.2 Close View of Condensate Distributor ...................................................................... 87
5.3 Recovery of Oxidation Catalyst with Resins ............................................................ 89
5.4 Mitsubishi Gas Chemicals Catalyst Recovery System .............................................. 94
5.5 Screen-Type Centrifugal Separator with an Inside Screw Conveyor ....................... 97
5.6 SABIC Oxidation Promoter against Conventional Initiator Performance ................. 98
5.7 Eastman Improved Terephthalic Acid Process ......................................................... 101
5.8 Conventional Oxidizer and Sam Nam Petrochemicals Reactor Comparison ............ 103

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5.9 Cross-sectional View of Reactant SNP Feed System ............................................... 104
5.10 PTA Process from PET .............................................................................................. 110
5.11 Effect of Water on PET Ethanolysis .......................................................................... 111
6.1 Terephthalic Acid Process Comparison, Percentage Basis ........................................ 132
6.2 Terephthalic Acid Process Comparison ..................................................................... 132
6.3 Forthcoming Plants Competitiveness, 2010-2015 ..................................................... 141
6.4 Forthcoming Plants Competitiveness, 2010-2015 ..................................................... 141
8.1 Global PTA Consumption.......................................................................................... 149
8.2 Global PTA Capacity Additions ................................................................................ 151
8.3 Global PTA Capacity ................................................................................................. 151
8.4 North America PTA Consumption, 2009 .................................................................. 153
8.5 West European PTA Consumption, 2009 .................................................................. 157
8.6 Asia Pacific Consumption, 2009................................................................................ 162

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Table Page
1.1 Comparison of Processes ........................................................................................... 10
1.2 Global PTA Consumption by End-Use...................................................................... 18
3.1 Molar Efficiency of Terephthalic Acid Technology .................................................. 28
3.2 Characteristics of PTA ............................................................................................... 33
3.3 Required Raw Material Characteristics ..................................................................... 35
3.4 COMPRESS™ PTA Product Specifications (Source: DPT) ..................................... 42
3.5 Typical PTA Specification ......................................................................................... 50
3.6 Typical Raw Material Specifications ......................................................................... 50
3.7 Typical Purification by Solvent Crystallization Efficiency ....................................... 65
4.1 Mitsubishi PTA History ............................................................................................. 78
4.2 PTA/QTA Impurity Levels ........................................................................................ 78
4.3 MCC QTA Specification ........................................................................................... 79
4.4 Mitsubishi Chemical Group PTA/QTA Capacity ...................................................... 79
4.5 Comparison of PTA and MTA Specifications ........................................................... 80
5.1 DET and Ethylene Glycol Recovered Using Various PET Flakes ............................ 109
5.2 DET/para-xylene Oxidation Results ......................................................................... 111
5.3 FDCA Conversion to TA ........................................................................................... 112
6.1 Pricing Basis for Terephthalic Acid ........................................................................... 113
6.2 Direct and General Overheads, Maintenance, Tax, and Insurance ............................ 115
6.3 Cost of Production Estimate for Purified Terephthalic Acid ..................................... 117
6.4 Cost of Production Estimate for: Purified Terephthalic Acid
Process: Oxidation/Hydrogenation (COMPRESS™) ................................................ 119
6.5 Cost of Production Estimate for: Purified Terephthalic Acid
Process: Oxidation/Hydrogenation (INVISTA 1.12 million tons per year
Capacity) .................................................................................................................... 121
6.6 Cost of Production Estimate for: Purified Terephthalic Acid
Process: Oxidation/Hydrogenation (INVISTA 700 000 tons per year Capacity)...... 123
6.7 Cost of Production Estimate for: Purified Terephthalic Acid
Process: Oxidation/Hydrogenation (BP).................................................................... 125
6.8 Cost of Production Estimate for: Purified Terephthalic Acid
Process: Oxidation/Crystallization (GTC Technology) ............................................. 127
6.9 Cosof Production Estimate for: Medium Terephthalic Acid
Process: EPTA (Eastman/Lurgi) ................................................................................ 129
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6.10 Comparison of Processes ........................................................................................... 130
6.11 Plants Considered....................................................................................................... 135
6.12 Cost of Production Estimated for North-East Asia (China)
Process: Oxidation/Hydrogenation ............................................................................ 136
6.13 Cost of Production Estimated for South Asia (India)
Process: Oxidation/Hydrogenation ............................................................................ 137
6.14 Cost of Production Estimated for Central Europe (Poland)
Process: Oxidation/Hydrogenation ............................................................................ 138
6.15 Cost of Production Estimated for Middle East (Oman)
Process: Oxidation/Hydrogenation ............................................................................ 139
6.16 Cost of Production Estimated for South America (Brazil)
Process: Oxidation/Hydrogenation ............................................................................ 140
6.17 Regional Competitiveness Cost Summary................................................................. 142
8.1 Global PTA Consumption.......................................................................................... 149
8.2 North American PTA Consumption by Region ......................................................... 153
8.3 North American PTA Consumption by End-Use ...................................................... 154
8.4 North America PTA Capacity, 2009 .......................................................................... 155
8.5 North American PTA Supply, Demand, and Trade ................................................... 156
8.6 West European PTA Consumption by End-Use ........................................................ 157
8.7 West European PTA Capacity, 2009 ......................................................................... 158
8.8 West European PTA Supply, Demand, and Trade .................................................... 159
8.9 Asia Pacific PTA Consumption by Region ............................................................... 161
8.10 Asia Pacific PTA Consumption by End-Use ............................................................. 161
8.11 Asia Pacific PTA Capacity, 2009 .............................................................................. 164
8.12 Asia Pacific PTA Supply, Demand, and Trade.......................................................... 167

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