Oe Repsol Polimeros Site 21nov2018

Repsol Polímeros, S.A.
Excellence Petrochemicals in the Portuguese

Industrial Cluster
Ordem dos Engenheiros – 21Nov2018
© © Repsol Polímeros, Sines, November 2018.

Site general description
1. Site history
2. Site and surrounding area overview
3. Site integration
4. Site main figures
5. Reliability improvement
6. Polyolefins products
7. Olefins other products
8. Sines Olefins and Polyolefins Markets
9. Significant investments in recent years
10. Ethylene worldwide market outlook
11. What’s next?
© Repsol Polímeros, Sines, November 2018. 2

Site history
1

1. Historical summary
1972-1976 1976-1980 1981-1988 1989-2004 2005- 2017

Decision Construction Star-up. First Acquisition & Modernization
• Government decision • Olefins plants running years merging and
to create a • Test-runs • NESTE acquires competitiveness
Petrochemical • Polyolefins plants polyolefins and rents
Complex at Sines in • Cracker capacity
• Performance tests olefins
the Early ’70s increase
• Utilities plants • BOREALIS succeeds
NESTE • EBA grades
• Foundation of two • Improvements in • DCS in all process
product quality • Construction of
companies: MTBE plants
CNP, olefins
• HDPE revamping • NG in steam boilers
EPSI, polyolefins • Feedstock • REPSOL acquires
adjustments • Decommissioning PP MTBE
• ISO certifications • Extensive use of LPG
• REPSOL acquires in Cracker
the Site late 2004 • Cable grades in HDPE
and LDPE

Site and surrounding area overview
2

Site location
Repsol
Polímeros
Sines
Lisbon
150 km Petrochemical
Harbour
Sines
© Repsol Polímeros, Sines, November2018. 6

Industrial Cluster
© Repsol Polímeros, Sines, November 2018.

2 Site and surrounding area overview
Site general view
Olefins WWT
Storage
Steam Cracker Butadiene

Power Plant
& Utilities MTBE
LDPE
HDPE
Polyolefins
Logistics

Petrochemical port facilities general view
Harbour
facilities

Site integration
3
© Repsol Polímeros, Sines, October 2018. 10

3. Site Integration
From Crude Oil to Polymers
RAW PROCESS I PRODUCTS PROCESS II PRODUCTS PROCESS III PRODUCTS

MATERIAL & RAW & RAW
MATERIAL MATERIAL
Refinery: Nafta & LPG Steam Cracker: Polymerization:

Poliolefins:
Crude Oil Olefins: Catalytic
Distilation and (C3, C4) Thermal HDPE
Ethylene process
cracking process Cracking process LDPE / EBA
Propylene

3. Site integration
Site production plants
Olefins
Butadiene 52 kt/a HDPE 145 kt/a
Poliolefins
Steam Cracker
Etileno 410 kt/a
Propileno 200 kt/a
PyGas 200 kt/a
FOPY 40 kt/a
M/ETBE 53 kt/a
LDPE 150 kt/a

3. Site integration
Interconnections
NG
POWER
R PLANT
E Bleed ethylene
F PFO FG HDPE
Steam Hydrogen
I Electricity
Utilities
N RGP Ethylene LDPE
E C
R R
Y Propylene E
A
Naphtha STEAM X
C PyGas
Propane CRACKER P
K
I Butane E O
M R Crude C4 1,3-Butadiene R
BUTADIENE
BUTADIENE
P Ethane T
MTBE
O
Raff 1
R
T Methanol/Ethanol PFO
M/ETBE
Raff 2

3. Site integration
Licensing technology and design capacities
Steam Cracker HDPE LDPE

• Mitsui
• Linde Petrochemical • CdF Chemie
Engineering Industries
• Front end • Bimodal Slurry • HP Autoclave

deethanizer Process Ziegler- Reactors up to
Natta Catalyst 2000 bar
• Startup in 1981 • Startup in 1981 • Startup in 1981
• Design capacity • Actual capacity • Actual capacity

of 410kta C2= of 145kta (mix of 150kta (mix
dependent) dependent)

3. Site integration
Licensing technology and design capacities
Butadiene MTBE Power Plant

• Nippon Zeon • UOP/Huels • Electrobel
• DMF extractive • Acidic cationic • Combined

distillation resins Heat & Power
Cycle
• Startup in • Startup in • Startup in

1982 1991 1981
• Design • Design • Design

capacity of capacity of capacity of
52kta 1,3-BD 48kta MTBE 3x190 t/h HPS

3 Site integration
Steam Cracker block diagram
Naphtha
Propane
Butane + Raff 2 Ethane recycle
C2-
Oil and Precooling
Cracking and Cracked Gas C2 Cold train
Water Drying C2 Splitter
Quenching Compression Hydrogenation Demethanizer
Quench Deethanizer
C3+
Process
Steam
C3
Depropanizer
Hydrogenation
FCC C3
Propane
recycle
C5+ H2 CH4
Pygas C3 Stripping
Debutanizer fraction fraction
C5 recycle Hydrogenation C3 Splitter
Pyrolysis Pygas Crude C4 Propylene Fuelgas Ethylene

Oil

3. Site integration
HDPE block diagram
Ethylene
Hydrogen
Propylene Ethylene to
Catalyst 1-Butene Steam Additives
Cracker
HDPE
Catalyst Polymerization Drying & Compounding Natural Pellet
Preparation Reaction Separation and Extrusion Classification
and Expedition
HDPE
Coloured Pellet
Classification
Solvent and Expedition
Distillation

3 Site integration
LDPE block diagram
Ethylene PRIMARY
COMPRESSOR
AT/BA MPR
SECONDARY
COMPRESSOR
Non-reacted
REACTOR ethylene
Initiators
HP SEPARATOR
Non-reacted
ethylene
MP SEPARATOR
BLEED COMPRESSOR LP SEPARATOR Additives
EXTRUDER
Ethylene to Steam Cracker
DEGASSING AND
PACKAGING
3. Site integration
Butadiene block diagram
Crude C4
1st Extractive
distillation
2nd
Butadiene Butadiene
1st Stripping Extractive
Compression Fractionation
distillation
Butadiene Offgas
Recovery Compression
Solvent
Lean DMF purification 2nd Stripping
TAR removal
Raffinate 1 Dimer Offgas 1,3-Butadiene

TAR

3. Site integration
MTBE block diagram
Raffinate 1 Methanol / Ethanol
Methanol /
Etherification Butenes
Washing Ethanol
Reaction Distillation
Purification
Water
H2 Complete
Saturation
Process
MTBE/ETBE Raffinate 2 Vent Gas

3. Site integration
Harbour block diagram
Site plants Harbour
Vaporization
Ethylene Liquefaction Cryogenic Storage Import / Export

Boiloff compression
Pumping
Propylene Cryogenic Storage Import / Export
Boiloff compression
1,3-Butadiene Storage Export
MTBE / ETBE Storage Export / Transfer
MeOH / EtOH Storage Import / Transfer
Naphtha Storage Import
Pygas Import / Export
CC4 Import / Export
PFO Export
Diesel Oil
Import

3. Site integration
Power plant block diagram
Electricity
Imported from grid
120 bar
22 MW
BPT ~
3 Main
Boilers
6 bar
21 bar
Auxiliary 46 bar
Boiler
Fuel Gas
Natural Oil Fuel Gas + Vinyl Acetylene + Off Gas
Pyrolysis Fuel Oil + Dimer
CT ~
3. Site integration
Within the Group
La Coruña Santander
Bilbao
products
raw materials
Tarragona
Products: North America
Puertollano
products Cartagena
Sines
raw materials
&
raw materials
products

3 Site integration
Within Sines Industrial Cluster
LPG logistics Local Resins plant

Local propane cavern Methanol Supplier
Utilities exchange Terminals Logistics and Operation
Local Oil Refinery

Energy national grid Naphtha, LPG, RGP,
MTBE, Natural Gas Diesel Oil operations
N2 supplier Pipelines passage
Electricity Supplier
Water Supplier Sines Port Administration Sines Containers Terminal XXI

Industrial Effluent receiver Electrical distributor

Site main figures
4

General
 440 employees and an average of 450 contractors
 Production around 1.000.000 t/y of Olefins and Polyolefins
 Exports 85 - 90% of its production for over 60 countries
 In the top 10 major Portuguese exporters
 60 - 70% of raw materials import and products export is made by sea

Certificates
ISO 9001-2015 ISO 50001-2011 SEVESO III ISCC EU

ISO 14001- 2015 (DL 150/2015) MTBE & ETBE
OSHAS 18001:2007

4 Site main figures
Repsol Química Competitiveness Plan
Globalization
Efficiency Differentiation
 Feedstock flexibility
Ability to take advantage of the business opportunities in an easy mode
 LPG cracking
Modulate the ratio between liquid/gas feedstock based on the market
 Energy efficiency
Minimize energy costs and take advantage of the LPG cracking yields
 Differentiation
New products and specialty applications for demanding markets

Repsol Sines highlights
• Steam Cracker
- Increase in production rates and utilization rate levels
- High LPG feedstock processing (20-60% ratio market prices optimized)
- Longest plant running period in history: 691 days (previous of 204 days)
- Reliability index above 98%
- Energy consumption 4% decrease (2013 baseline)
- Process Losses 35% reduction (2013 baseline)
• Butadiene
- Moderate rates and occupation levels due to Cracker CC4 unavailability & market shortage
- Longest plant running period in history: 893 days
- Plant production records in 2016 due to spot CC4 availability
- First time in history plant follows site turnaround period (2012-2018)
• bio-ETBE / MTBE
- Low rates and occupation levels due to Butadiene Raffinate unavailability & market shortage
- Longest plant running period in history: 647 days
- Very high reliability index
- Operation mode switch from/to MTBE to/from bio-ETBE in 2015 and 2017
Repsol Sines highlights
• HDPE
- New cable grades development and production
- Last 12 years continuous on stream period record without plant
shutdowns – 125 days
- Increase in production rates
- Energy consumption 5% decrease (2013 baseline)
• LDPE / EBA
- Record of 133 days continuous on stream period of both LDPE L 1 and L2
- Record of 157 days continuous on stream period of both LDPE L1
- Record of 97,1% plant utilization rate (best ever)
- High reliability indexes
• Power Plant and Utilities

- Cracker-Power Plant integration in steam/fuels due to LPG cracking
- Increase of internal electrical production – change to self-producing
regime
- Backpressure turbine derating – efficiency increase
Reliability Improvement
5

4. Reliability Improvement
Reliability programme
Common project to all Repsol production
sites
It started in Sines in 2015
Multidisciplinary Cells lead by Operations
Root Cause Analysis based in Lean

Methodology
Safety enhancement by knowing the

failure mechanisms and acting
proactively
DailyFlow just started onsite

4. Reliability Improvement
Reliability Sines Site
Sines Site Reliability Index

100,0
98,0
96,0
94,0
92,0
90,0
2014 2015 2016 2017
Sines Site Repsol Chemical Division 2017

Polyolefins products
6

6. Sines polyethylene grades
Polyethylene pellets
 Polyethylene is the most important final product from Sines Complex
 High chemical stability

material
 Easy to sterilize and

manipulate
 Can be easily recycled and

reused

Applications for High Density Polyethylene (HDPE)
Family grades:
● Pipe: piping for water, gas and effluents
● Fibers: ropes, fishing nets, packaging for agro-products
● Moulding: packaging for hygiene, cleaning products and lubricants
● Film: food package and bags
● Electrical cables: isolation for LV and communication cables
Applications for Low Density Polyethylene (LDPE)
Family grades:
● Film: food package, bags and coating/lamination
● Injection: food package
● Retractable film: packaging (EBA)
● Foams and profiles: household and footwear (EBA)
● Electrical cables: coating for HV and VHV power cables (EBA)

Olefins other products
7

7. Olefins products and markets
Products
● Olefins are another important family of products exported by the Site
 Propylene, raw material to polypropylene
 1,3-butadiene, raw material for synthetic rubber.
 Pyrolysis gasoline, for benzene extraction
 M/ETBE, to improve octane rating in commercial

fuels.

Sines Olefins and Polyolefins Markets
8

8. Markets
2013-2017 worldwide (Olefins + Polyolefins)
1% 84%
EUA & Europa
Canadá
3%
Ásia &
Extremo Oriente
5%
África &
7% Médio Oriente
América
Latina

8. Markets
2013-2017 Europe (Olefins + Polyolefins)
7% 4% 2%
34% 26% 20% Bélgica França Itália
Espanha Holanda Alemanha
2%
Grécia
1%
Reino Unido
© Repsol Polímeros, Sines, October 2018.

Significant investments in recent years
9

Raw gas turbine and condenser

16 M€
Furnaces convection revamping

12,7 M€
Electrical grid and substations

10,3 M€
Motor Hypercompresor L2LDPE

3,6 M€

70
[M€]
60
50
40
30
20
10
0
2012 2013 2014 2015 2016 2017 2018
Total 80M€ between site turnarounds

Safety and Environment [M€] Renovation [M€]

7 7
6 6
5 5
4 4
3 3
2 2
1 1
0 0
2013 2014 2015 2016 2017 2013 2014 2015 2016 2017
Infrastructures & Other

Development & Efficiency operational improvements
[M€] [M€]
7 7
6 6
5 5
4 4
3 3
2 2
1 1
0 0
2013 2014 2015 2016 2017 2013 2014 2015 2016 2017

Ethylene worldwide market outlook
10

10. Ethylene market outlook

10. Ethylene market outlook

What’s next?
11

11. What’s next?
Competitiveness, flexibility and resilience…

Thank you
© © Repsol Polímeros, Sines, November 2018.

Oe Repsol Polimeros Site 21nov2018

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Repsol Polímeros, S.A.

Excellence Petrochemicals in the Portuguese

Ordem dos Engenheiros – 21Nov2018

© © Repsol Polímeros, Sines, November 2018.

© Repsol Polímeros, Sines, November 2018. 2

© Repsol Polímeros, Sines, November 2018. 3

1972-1976 1976-1980 1981-1988 1989-2004 2005- 2017

© Repsol Polímeros, Sines, November 2018. 4

© Repsol Polímeros, Sines, November 2018. 5

© Repsol Polímeros, Sines, November2018. 6

© Repsol Polímeros, Sines, November 2018.

Steam Cracker Butadiene

© Repsol Polímeros, Sines, November 2018.

© Repsol Polímeros, Sines, November 2018.

© Repsol Polímeros, Sines, October 2018. 10

RAW PROCESS I PRODUCTS PROCESS II PRODUCTS PROCESS III PRODUCTS

Refinery: Nafta & LPG Steam Cracker: Polymerization:

© Repsol Polímeros, Sines, November 2018. 11

Butadiene 52 kt/a HDPE 145 kt/a

© Repsol Polímeros, Sines, November 2018.

© Repsol Polímeros, Sines, November 2018.

Steam Cracker HDPE LDPE

• Front end • Bimodal Slurry • HP Autoclave

• Startup in 1981 • Startup in 1981 • Startup in 1981

• Design capacity • Actual capacity • Actual capacity

© Repsol Polímeros, Sines, November 2018.

Butadiene MTBE Power Plant

• DMF extractive • Acidic cationic • Combined

• Startup in • Startup in • Startup in

• Design • Design • Design

© Repsol Polímeros, Sines, November 2018.

Pyrolysis Pygas Crude C4 Propylene Fuelgas Ethylene

© Repsol Polímeros, Sines, November 2018.

© Repsol Polímeros, Sines, November 2018.

BLEED COMPRESSOR LP SEPARATOR Additives

Raffinate 1 Dimer Offgas 1,3-Butadiene

© Repsol Polímeros, Sines, November 2018.

Raffinate 1 Methanol / Ethanol

MTBE/ETBE Raffinate 2 Vent Gas

© Repsol Polímeros, Sines, November 2018.

Ethylene Liquefaction Cryogenic Storage Import / Export

Propylene Cryogenic Storage Import / Export

1,3-Butadiene Storage Export

MTBE / ETBE Storage Export / Transfer

MeOH / EtOH Storage Import / Transfer

Naphtha Storage Import

Pygas Import / Export

CC4 Import / Export

© Repsol Polímeros, Sines, November 2018.

Products: North America

© Repsol Polímeros, Sines, November 2018.

LPG logistics Local Resins plant

Utilities exchange Terminals Logistics and Operation

Local Oil Refinery

Water Supplier Sines Port Administration Sines Containers Terminal XXI

© Repsol Polímeros, Sines, November 2018.

© Repsol Polímeros, Sines, November 2018. 25

 440 employees and an average of 450 contractors

 Production around 1.000.000 t/y of Olefins and Polyolefins

 Exports 85 - 90% of its production for over 60 countries

 In the top 10 major Portuguese exporters

 60 - 70% of raw materials import and products export is made by sea

© Repsol Polímeros, Sines, November 2018. 26

ISO 9001-2015 ISO 50001-2011 SEVESO III ISCC EU