-SABLIN TECHNOLOGY STORY OF CHALLENGE AND SUCCESS

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1 -SABLIN TECHNOLOGY STORY OF CHALLENGE AND SUCCESS

2 SABIC TECHNOLOGY AND INNOVATION

3 A STORY OF SABIC INNOVATION ( LATE 80 S) No. 2

SABIC JOURNEY TOWARDS INNOVATION Started with less than 10 scientists 1989 First Sabic R&D in Riyadh 1996 Sabic Technology Center Houston 1999

2000 scientists and Research staff Developed 10 new technologies Developed 150 + new products yearly 10000 global patents.

4 SABIC JOURNEY TOWARDS INNOVATION Started with less than 10 scientists 1989 First Sabic R&D in Riyadh 1996 Sabic Technology Center Houston 1999 Demonstration of Sabcat-1 at PK 2005 Start-up of 1 st Acetic Acid Plant at Yanbu 2006 Start-up of 1 st LAO Plant in Jubail th Centers Globally 2000 scientists and Research staff Developed 10 new technologies Developed new products yearly global patents Global Solution Provider Start up with technology licensing-in and JV s Maintain and improve Licensed technology Develop and Innovate new technologies Global Solution Provider No. 3

5 LIVING A CULTURE OF INNOVATION Predict + Repeat Minimize Risk Learn + Adapt Manage Risk Never Fail Invention (T&I) Activities Fail Early + Cheaply Innovation (All) Results No. 4

6 SABIC TECHNOLOGY AND INNOVATION NETWORK BoZ USA AC Houston Geleen Shanghai Moka Cartagen Jubail a Thuwal VDD Riyadh Bangalore Research Centers Application Centers SABIC Plastic Application Center at KSU, Riyad SABIC Corporate Research & Innovation Center at KAUST No. 5

7 α-sablin Competing LAO Technology

get a license for 1-Hexene production technology CP and SHELL declines to

8 -SABLIN : THE RATIONALE BEHIND TECHNOLOGY DEVELOPMENT SABIC ranks 3 rd in world as PE producer + Mid 90 s challenge in 1-Hexene supply SABIC decides to get a license for 1-Hexene production technology CP and SHELL declines to give license 1995 SABIC Management decides to develop in-house/joint technology No. 7

9 WHAT IS LINEAR -OLEFINS Linear alpha Olefins (LAO s) are linear hydrocarbon consisting of an even carbon atoms (C4 C20+) Linear alpha Olefins (LAO s) can be synthesized by catalytic ethylene oligomerization Name C n H 2n Structure Mol. Mass Boiling point C Melting point C Butene-1 C 4 H 8 CH 3 -CH 2 -CH=CH ,2-185,3 Hexene-1 C 6 H 12 CH 3 -(CH 2 ) 3 -CH=CH ,5-140,0 Octene-1 C 8 H 16 CH 3 -(CH 2 ) 5 -CH=CH ,3-102,7 Decene-1 C 10 H 20 CH 3 -(CH 2 ) 7 -CH=CH ,6-66,6 Dodecene-1 C 12 H 24 CH 3 -(CH 2 ) 9 -CH=CH ,3-33,6 Tetradecene-1 C 14 H 28 CH 3 -(CH 2 ) 11 -CH=CH ,0 Hexadecene-1 C 16 H 32 CH 3 -(CH 2 ) 13 -CH=CH ,0 Octadecene-1 C 18 H 36 CH 3 -(CH 2 ) 15 -CH=CH ,5 Eicosene-1 C 20 H 40 CH 3 -(CH 2 ) 17 -CH=CH ,8 C 4 = Gas; C 6 to C 18 = Liquid; C 20 to C 30+ = colorless wax No. 8

GENERAL APPLICATIONS OF LINEAR -OLEFINS Applications:

8 ) Base stock for detergents (linear alcohols and

Base stock for lubricants (Polyalpha-olefins),C 10 Base

Surfactants (C 16 -C 18 ) Detergent Lubricants, 15%

10 GENERAL APPLICATIONS OF LINEAR -OLEFINS Applications: Commoner for polyethylene production HDPE and LDPE (C 4 C 8 ) Base stock for detergents (linear alcohols and linear-alkylbenzenes( C 12 -C 18 ) PE Bottles Wax Polish Base stock for lubricants (Polyalpha-olefins),C 10 Base stock for plasticizer, PVC (C 6 -C 10 ) Amines and Surfactants (C 16 -C 18 ) Detergent Lubricants, 15% Plasticizer s, 6% Detergents, 25% Shampoo Others, 4% Lubricant Polymers, 50% No. 9

11 GLOBAL LAO TECHNOLOGIES Competitors 1&2 Single Product Competitor Competitor 3 -SABLIN bar 50 bar 140 bar bar C 110 C 120 C C Low product No flexibility Expensive High product flexibility (1-hexene) heavy metal flexibility Toxic heavy catalyst Economically metal catalyst attractive No. 10

12 Technologies Product Distribution (wt%) Process Competitors 1&2 Competitor 3 -SABLIN Alpha Olefin heavy light typical heavy medium light C 4 13,9 22,9 12 6,1 24,0 40,2 C 6 14,6 20,6 13 6,2 27,1 28,1 C 8 13,7 16, ,2 13,2 14,0 C 10 12,0 12, ,3 11,2 8,4 C 12 10,0 8, ,6 8,3 5,0 C 14 8,2 6,2 8 12,0 5,8 2,3 C 16 6,5 4,3 7 10,0 4,8 1,4 C 18 5,2 2,9 6 8,2 2,9 0,5 C ,9 5, ,4 2,8 0,1 No. 11

-SABLIN - DEVELOPMENT HISTORY 2009 Full Tech. commercialization End of 2006 1st commercial unit y(1) 4 3 2 2001 demonstration -SABLIN 1 y(2) 0 0 20 40 60 80 100 120 t 1 0.8 0.6 0.

13 -SABLIN - DEVELOPMENT HISTORY 2009 Full Tech. commercialization End of st commercial unit y(1) demonstration -SABLIN 1 y(2) t start up LAO pilot plant t Since 1997catalyst development 1997 LINDE/SABIC LAO cooperation 1995 Catalyst concept from ICP and Prove of Reaction No. 12

14 -SABLIN - THE SUCCESS STORY OF CATALYST 3x Kg of LAO/g of catalyst Commercial Scale Catalyst Surface to volume ratio How to make a proper catalyst x Kg of LAO/g of catalyst A perfect catalyst system Issue Stable Zr based Catalyst with modified Al CoCatalyst to enhance catalyst performance No. 13

15 -SABLIN - THE INITIAL RUNS IN PILOT PLANT BENCH SCALE PILOT SCALE REACTOR VALVE GAS DISTRIBUTOR Almost Clean Not much signs of polymers Polymers everywhere in the pilot plant SYSTEM NEEDS THOROUGH CLEANLINESS / Short Run length No. 14

16 -SABLIN - THE LATER REALIZATION IN PILOT PLANT A team of experts for thorough brainstorming sessions Revamp of pilot plant design / Modified start-up ot SUCCESSFUL RUNS Results: Extended run length of reactor No. 15

17 -SABLIN - THE CHALLENGES DURING DESIGN Selection of Reactor Exothermic Reaction Cooling Avoiding Polymer Build-up In-situ regeneration of the reactor loop No. 16

18 - SABLIN - SELECTION OF REACTOR Criteria: Exothermicity Ethylene, Light LAO s Reflux Polymer Handling Catalyst Solvent Ethylene TOS (min.) Heavy LAO s, Catalyst No. 17

Pilot plant Mechanical cleaning takes several days -SABLIN - Solution An in-situ flushing concept

19 - SABLIN - IN-SITU FLUSHING Polymer formation An inherent feature of any oligomerization technology Also seen in - SABLIN Technology Challenge How to reduce down time Not Pilot plant Mechanical cleaning takes several days -SABLIN - Solution An in-situ flushing concept No Mechanical Cleaning Increases On Stream factor Distribution Plate after in situ regeneration with solvent No. 18

Product Separation 1-Butene Solvent Recycle 1-Hexene C2 Make-up

20 - SABLIN - 4 BASIC PROCESS STEPS Feedstock and Catalyst Preparation Reaction and Catalyst Removal Primary Separation Product Separation 1-Butene Solvent Recycle 1-Hexene C2 Make-up 1-Octene LAO Reactor Catalyst Removal 1-Decene Catalyst C4+ C8+ C12+ No. 19

21 - SABLIN - START-UP INAUGURATION No. 20

- SABLIN - Accelerated Start-up of Commercial Plant

Start-up Huge amount of undesired polymers Pluggages

any solvent Caused by metal residue/corrosion The pain

22 - SABLIN - Accelerated Start-up of Commercial Plant Pre-Commissioning Phase reduced for an accelerated Start-up Huge amount of undesired polymers Pluggages of lines Highly cross-linked polymers Not dissolved by any solvent Caused by metal residue/corrosion The pain of SHORT CUTS! Ensure thorough cleaning of the system No. 21

23 - SABLIN - THE PRESENCE What OF CORROSION is the Issue Spot shot from Chloride base corrosion traces affecting the Separation Train Catalyst Feed Recycle C 4 C 8 (Light) Reaction Section Deactivation Section Separation Section C 10 C 12 (Medium) Ethylene + Solvent C 12 C 20+ (Heavy) No. 22

24 What is Possible Source of Chloride - SABLIN - CATALYST DEACTIVATION The Concept: reactor bottoms effluent LAO, Solvent, Catalyst Catalyst killing agent (CKA), water mixing LAO to separation train LAO, Solvent, Chlorides CKA, water, Metal Oxides triggered by uncompleted catalyst removal Mechanical mixers not a solution Pilot Plant: Catalyst dosing y kg/hr Chlorides in ppm level no efforts on detection NO SIGNS OF CORROSION (Presence of adsorber) CKA circulation Commercial Plant: Catalyst dosing y kg/hr Chlorides in ppb level SEPARATION COLUMN BADLY CORRODED (No adsorber, triggered by FeClx, water and high temperature) No. 23

25 - SABLIN - BENEFITS OF DOSING CHEMICAL X No OC formation! from decantation Reactor vvvvvvvvvvv Decantation To LAO Separation Chemical X dosing to mixers No. 24

RISK AND CHALLENGES DURING THE OVERALL PROCESS From a project planning and resource management perspective, it is important to recognize that higher risk projects increase volatility of planning and

26 RISK AND CHALLENGES DURING THE OVERALL PROCESS From a project planning and resource management perspective, it is important to recognize that higher risk projects increase volatility of planning and the potential need for additional resources and additional schedule. This should be factored into the project plan and a risk reserve provided in the form of budget and the resources to address risk issues. No. 25

27 TAKE OUT FROM THE CHALLENGE A Technology development route will consist of chemistry discovery, measurement of kinetic, reactor modeling, conceptual design, pilot plant study, flow sheet optimization and finally engineering. All these require a seamless workflow that can be achieved using the group of tools. These tools continuously interact with each other all along the course of technology development to enhance and speed up the technology commercialization capability. Important to manage Ressource selection, Time prussure, Project planning. Identify critical issues at early stages. Allow some design felxibility which cost some money but help optimizing alot of process and product limitation. No. 26

28 -SABLIN - HIGHLIGHTS A full-range process One-step from Ethylene Product Slate Flexibility Operator friendly Attractive economics All Reflected in 2 nd SabLin plant being constructed now in Russia and plan to be started Q1, 2016 Strongly covered by Patents Proprietary Owned License can be offered LAO Process Team 27 No. 27

29 -SABLIN - SAFE LAO TEAM No. 28

30 No. 29

NOVEL ROUTES IN CO 2 UTILIZATION: A SUSTAINABLE APPROACH. Dr. Khalid Albahily SABIC CRD at KAUST

NOVEL ROUTES IN CO 2 UTILIZATION: A SUSTAINABLE APPROACH Dr. Khalid Albahily SABIC CRD at KAUST SABIC AT-A-GLANCE 1976 34,000 50 3 rd 120 th 4 Company established Employees around the world Countries of