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Malaysiancompanymorethandoubles
petchemcomplexcapacity
07/03/2000

Titan'snewestcrackerhasacapacityof330,000tpyofethyleneand
165,000tpyofpropylene.ThenaphthacrackingfurnaceusesStone
&WebsterInc.'sUltraSelectiveCracking(UCS)technology.Photos
courtesyofTitanPetrochemicalsSdn.Bhd.(Fig.1)
Clickheretoenlargeimage

TitanPetrochemicalsSdn.Bhd.,thelargestpetrochemicalcompanyinMalaysia,commissionedanew
330,000tonnes/year(tpy)ethyleneunitinPasirGudang,Johor,Malaysia,inOctober1999.The
crackercanalsoproduce165,000tpyofpropylene(Fig.1).

Clickheretoenlargeimage

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ThenewunitbringsthecapacityofthePasirGudangcomplexupto560,000tpyethyleneand280,000
tpyofpropylene,drivingupitseconomiesofscale.
Thisethyleneplantwaspartofalargerexpansionprogram,encompassingseveralpolyolefinunits.
MostoftheethyleneproductisfeedforTitan'spolyethylene(PE)andpolypropylene(PP)plants.
Remainingethylenegoestothemerchantmarket.ThePPplantstakeallofthepropylene.
Thenewaromatics(BTX)complex,commissionedinJanuary2000,takesthepyrolysisgasolinefrom
BTX
thesenaphthacrackers.

Clickheretoenlargeimage
Fig.2showsthestructureofTitan'sintegratedpetrochemicalcomplex.TheTitanGrouphasthree
operatingcompanies:TPC,TPE,andTPP.
TPCisresponsiblefortheproductionofethyleneandpropylene.TPEprimarilyproduceslowdensity
PE(LDPE),lowlineardensityPE(LLDPE),andhighdensityPE(HDPE).TPPownsandoperatestwo
PPplants.
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TheownershipstructureoftheTitanGroupiscomposedoftheChaofamily(viaUHI48.8%),PNB(via
PERC45.5%),Sinochem(viaSCP1.3%),andotherminorityshareholders(4.4%).
Petchemcomplex

TheTitanGroupisoneofonlytwoproducersandsuppliersofPEandPPinMalaysia.ItsPasir
Gudangpetrochemicalcomplexconsistsofseveralplants:

TwonaphthaandLPGcrackerswithacombinedcapacityof560,000tpyofethyleneand
280,000tpyofpropylene.
A200,000tpyswingHDPEandLLDPEplant.
A200,000tpyLDPEplant.
TwoPPplantswhichproducePPhomopolymersandPPcopolymers.Theyhavea
combinedcapacityof330,000tpyofPP.
ABTXplantthatproduces108,000tpyofbenzeneand60,000tpyoftoluene.
BTX
Varioussupportfacilities,includingcogenerationpowerplants,tankfarms,and
warehouses.

ThedevelopmentofTitan'spetrochemicalcomplexconsistsoftwophases.
InPhaseI,TitandevelopedthefirstnaphthaandLPGcracker,theswingHDPEandLLDPEplant,and
thefirstPPplantona33hectaresite.Thisinitialdevelopmentcostabout$661million(1.65billion
Ringgit).
PhaseII,initiatedinlate1996andmostlycompletedbyearly2000,morethandoubledthesizeand
capacityofTitan'spetrochemicalcomplex.ItexpandedthecomplexbeyondthePasirGudang
IndustrialEstateontoa40hectaresiteinthenearbyTanjungLangsatIndustrialEstate.
Atacostofabout$840million(RM3.2billion),PhaseIIincludedtheconstructionof:

Thesecondcracker,whichhasacapacityof330,000tpyofethyleneand165,000tpyof
propylene.
The200,000tpyLDPEplant.
ThesecondPPplantwithacapacityof200,000tpy.
Anew100,000tpyHDPEplant.
TheBTXplant.
BTX
Twonewcogenerationpowerplants,whichproduceelectricityandsteamfor
petrochemicalcomplexesatbothPasirGudangandTanjungLangsatIndustrialEstates.
Newpipelines,tankfarms,andwarehouses.

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Thecogenerationplantsarefueledbytwosources:gassuppliedviaapipelinebyPetroliamNasional
Bhd.(Petronas),Malaysia'snationalpetroleumcorporation,andfuelgasandwasteenergyfromthe
crackers.
PhaseIIislargelycompleteexceptfortheHDPEplant,whichwillcomeonlineinthethirdquarterof
2000.

Clickheretoenlargeimage
Table1breaksoutthelicensorsandengineeringandconstructioncontractorsforeachunit.
SeveralnewpipelineswerecompletedinOctober1999.Five12kmundergroundpipelineslinkthe
PasirGudangandTanjungLangsatIndustrialEstate,thesiteofthenewLDPEandHDPEplants.
Theseallowfortransportationofethylene,propylene,butene,andnaturalgas(forusebythe
cogenerationplant).
OthernewpipelinesconnectthepetrochemicalcomplexwiththeJohorPortandthetankfarms.

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Duringpeakconstruction,therewereabout5,000constructionemployeesonsite.Withthecompletion
ofthenewHDPEplant,thecurrent1,075personnelpermanentworkforcewillincreaseby4050
persons.
PEandPPmarket

Titanproduces30gradesofPPproductsand37gradesofPEproducts.
MalaysianconsumptionratesofPEandPParegrowingfast.Beforethe1990s,therewasnodomestic
PEorPPproduction,accordingtoTitan.In1999,Titansoldabout86%ofitsPEproductsandabout
80%ofitsPPproductsinthedomesticmarket.
Inthesameyear,TPCsoldabout63%ofitsethyleneproductiontoTPEandTPP.Allofitspropylene
productionwenttoTPPasfeedstockfortheproductionofPP.
In1999,about75%ofthePEthatTitansoldtotheMalaysianmarketwasprocessedintofilmthe
balancewasusedforinjectionmouldingandblowmoulding.
WiththenewHDPEplantonstream,Titanwillbeexportingupto50%ofitspolymerproduction.
Titan'sPPproductsinclude16gradesofhomopolymersand14gradesofrandomandblock
copolymers.ThecompanybelievesitistheonlyproducerofcopolymersinMalaysia.While
homopolymershavegoodclarity,highstiffness,goodchemicalandrelativelyhightemperature
resistance,theyhavelowimpactresistance.Randomcopolymers,incomparison,havehigherclarity,
greaterimpactresistance,andmoreflexibility.Blockcopolymershavebetterimpactstrengthatlower
temperaturesandhighermeltingpointsthanrandomcopolymers.
In1999,about42%ofTitan'sPPsoldinMalaysiawasusedforinjectionmoulding.Thebalancewas
processedintofilmandyarn.
Tariffsandtaxes

MalaysianmanufacturingcompanieshavehistoricallybenefitedfromtariffsonimportedPEandPP.
Thecurrenttariffis15%forimportsfromtheAssociationofSoutheastAsianNations(ASEAN)
countriesand30%forimportsfromnonASEANcountries.Theintentsofthesetariffsweretostimulate
growthinthedomesticpetrochemicalindustryandreduceMalaysia'sdependenceonimports.
TitanexpectstariffsonASEANimports,however,tobeloweredoreliminatedby2003.Thecompany
believesitisprotectedfromtheincreasedcompetitionthatlowertariffsmaybring,however,because
anyincreaseincompetitionintheMalaysianmarketshouldbeoffsetbytariffreductionsinother
ASEANmarkets.
UnderthePromotionofInvestmentsActof1986,thegovernmentofMalaysiagrantedallTitan
operatingcompaniesOldPioneerstatus.OldPioneerstatusisa100%taxexemptiononprofit.
Theexemptionisapplicablefor5yearsuponcommencementofcommercialproduction.TPPandTPE
havebothsuccessfullyextendedtheir5yearPioneerstatusuntilDec.31,2001,andNov.30,2003,
respectively.TPChasalsoreceiveda5yearextension,dueonApr.30,2004.
Naphthacrackers
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ThefirstnaphthaandLPGcracker,commissionedin1994,hadaninitialnameplatecapacityof230,000
tpyofethyleneand115,000tpyofpropylene.Titancommissionedthesecondcracker,capableof
producing330,000tpyethyleneand165,000tpyofpropyleneinOctober1999.

Clickheretoenlargeimage
Fig.3showsageneralflowdiagramofthesetwoethyleneplants.
AlthoughbothcrackerscanuseacombinationofnaphthaandLPGforfeed,inpractice,thecrackers
useonlynaphtha.
Priortothecommissioningofthesecondcracker,Titanrequired600tpyofnaphtha.Today,Titan
requires1,600tpyofnaphtha.
AsthereisnoadjacentrefineryinPasirGudang,Titanreliesonexternalsourcesforitsnaphtha
supply.ThecompanyhasnaphthasupplycontractswithSaudiArabianOilCo.,ShellInternational
EasternTradingCorp,KuwaitPetroleumCorp.,andMarubeniInternationalPetroleum(Singapore)Pte.
Ltd.
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Thefeasibilitystudyforthesecondnaphthacrackerbeganinthesecondhalfof1996construction
beganinFebruary1997.TitanchosetousetwomainprocesstechnologiesbyStone&WebsterInc.:
UltraSelectiveCracking(UCS)forthepyrolysisandquenchsystemsandAdvancedRecovery
System(ARS)forcoldfractionation.
ThechoiceofARStechnologywasforbothconvenienceandperformance.Titanhashadgood
experiencewiththetechnologyinitsfirstcracker.ARSalsometplantlayoutconsiderationsandis
easytoscaleupincapacity.Furthermore,Titanwasabletoreusesomeoftheoriginaldetailed
engineeringfromthefirstcracker.
TitanalsochosetheARStechnologyforitsenergyefficiency:

Reducedchillingtrainrefrigerationloadinthedephlegmator.
Simultaneouschillingandprefractionationinthedephlegmator.
Reducedmethanecontentinthefeedtothedemethanizer.
Reduceddeethanizerload(C2streambypassesthedeethanizerandgoesdirectlyto
theethylenefractionator).
Dualfeedethylenefractionator(lowerrefluxratio).
Reducedrefrigerationdemand(10%overallenergyreduction).

BTXplant

Thebyproductsofthecrackersarepyrolysisgasoline,gaseousfuels,fueloils,andgaseoushydrogen.
The$41millionBTXplant,completedinJanuary2000,sitsadjacenttothesecondcrackerandshares
BTX
commonfacilitieswithit.Aftertheplant'scommissioning,TPCdivertedits337,000tpypyrolysis
gasolinebyproductfromtheexportmarkettothenewBTXplant.
BTX
TheproductionprocessoftheBTXplantbeginswhenpartiallyhydrogenatedpyrolysisgasolineis
BTX
pipedtoasplittertoremovemixedxylenes.BASFAG'sSelopFC5+processhydrogenatesthe
resultantproduct.TheextractivedistillationsectionusesKruppUhde'sMorphylaneprocess,toextract
benzeneandtoluene.
Wasteproductsaresentbacktothecrackersforcrackingwhilebenzeneandtoluenearesenttoa
towerforremovalofsolvents.Thetowerseparatesthebenzeneandtolueneandsendsthemto
storagefacilities.
Polyethyleneplants

Theswing200,000tpyHDPEandLLDPEplantwascompletedinSeptember1993.ItusesUnion
CarbideCorp.'sUnipolgasphase,lowpressurePEprocesstechnology.
TPEalsoownsandoperatesthenewLDPEplant,whichbegancommercialoperationsinNovember
1999.MitsuiEngineering&ShipbuildingCo.Ltd.constructedtheplantusingExxonMobilChemical
Co.'shighpressuretubularPEtechnology.Thecapitalcostoftheplantwasabout$152million,
includinglandcosts.
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TheExxonMobiltechnologyproducesawiderangeofLDPEgrades,includinggradesthatcanbeused
toproduceahighclarityoffilm,amajormarketsegmentforLDPEinMalaysia.
EthylenefeedstockfortheLDPEandtheHDPE/LLDPEplantscomesviapipelinefromTitan's
crackersorfromTitan'scryogenicstoragefacilitiesadjacenttoJohorPort.
ForHDPEandLLDPE,buteneorhexeneactsascomonomerswithethylenetoproducepolyethylene.
Therawmaterialsgothroughapurificationprocesstoremovetraceimpuritiessuchasoxygenand
waterbeforetheyareinjectedintothereactioncycleforpolymerization.Polymerizationtakesplaceina
fluidizedbedreactor,whereacatalystpromotesreaction.TherawmaterialsaretransformedintoPE
powder,whichisdischargedfromthereactortothepurgebin.
Inthepurgebin,thePEpowderridsitselfofresidualethylene.AlargeextrudermeltsandcutsthePE
powderintosmallpellets.Titanstoresthepelletsinsilos,fromwheretheyarepackagedandlabeled
"Titanex"fordistribution.
LDPEproductioninvolvesreactingethylenewithperoxideinitiators.Theethyleneispumpedintoa
milelongtubularreactor,whichissplitintofivezonesofincreasingpressure,uptoamaximumof
3,000bar.

ThelowpressurerecyclesysteminthenewLDPEunit,
commissionedinNovember1999,recyclesthelowpressuregasto
recoverethylene.PhotocourtesyofTitanPetrochemicalsSdn.Bhd.
(Fig.4).
Clickheretoenlargeimage

Ateachstage,theLDPEprocessinjectsperoxideinitiators.Atthefinalstage,LDPEisformedasa
stickypaste.Thepressureisthenreduced,anddegassingandchillingtakeplace.Excessethyleneis
recycled(Fig.4).TheLDPEisextractedandcutintopelletsinanunderwaterpelletizer.
TechnipGeoproduction(Malaysia)Sdn.Bhd.,KualaLumpur,isconstructingthenew100,000tpy
HDPEplantatTanjungLangsat.Thecapitalcostofthisplantisabout$75million.
TheHDPEproductwillbeusedforhighqualityfilmsandhighqualitypipesforwaterandgas.Unlike
theLLDPE/HDPEplant,whichusesagasphaseprocess,thenewHDPEplantwillemployMitsui
ChemicalsInc.'sCXprocess,alowpressureliquidslurryprocess.
FeedstockforthenewHDPEplantwillcomefromTPC'scrackers.

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TitanwillmarketitsnewLDPEproductunderthename"Titanlene"andproductsfromthenewHDPE
plantunder"Titanzex."
Polypropylene

TPPownsandoperatestwoPPplantswithacombinednameplatecapacityof330,000tpy.Thefirst
PPplantwascompletedinDecember1991,andthesecondplantstartedcommercialoperationin
September1999.Thesecondplantcostabout$96milliontobuild.
Thefirstplantinitiallyhadacapacityof100,000tpyofPP.Titandebottleneckeditin1996toincrease
thecapacityto130,000tpy.Titansizedthesecondplanttoconsumeallthepropylenethatwouldbe
producedbythetwonaphthacrackers.
BothplantsuseMontell'sSpheripolPPprocess.Spheripolusesahighyield,highstereospecific
catalystinatwostagepolymerizationsystem.
Thetwoplantssharesomecommonfacilitiesandmanpower,whichlowerstheinitialinvestmentcost
forthenewPPplantandtheoveralloperatingcostsforbothplants.ThesecommonfacilitiesallowTitan
tobenefitfromeconomiesofscale,awiderproductrange,betteroperationalefficiency,andmore
efficientproductionscheduling.
ThePPplantsobtainmostoftheirpropylenebypipelinefromTPCthebalanceisimported.
TheproductionofPPinvolvesreactingpropylene,aliquefiedgas,inthepresenceofacatalyst.
Polymerizationoccursintheloopreactors.Plasticresin,theresultingmixtureofpropyleneand
catalyst,isseparatedinthepropylenerecoverysection.
ThePPisthentransferredtotheextrusionsection,whereadditivesaremixedwiththePPbymelting
andmixinginanextruder.AdditivesmodifythePPforeachtypeofuse.Themoltenmixtureinthe
extruderisthenblendedthroughadie,cut,andthencooledintosmallpellets.Titansellsthesepellets
underthename"Titanpro."
Supportfacilities

Titansupportfacilitiesincludewarehouses,tankfarms,andaccesstojettyfacilitiesattheJohorPort.
PhaseIIaddedthreenewwarehousestoTitan'sexistingtwo.ThefivewarehousesstorePEandPP
andhaveacombinedcapacityof56,700tonnes.
PhaseIIalsoincludesanewtankfarmwithfivenewtanksforthestorageofnaphtha,benzene,and
toluene.TitanownedtwoothertankfarmspriortothePhaseIIproject:onetankfarmforthestorageof
ethyleneandpropyleneandonetankfarmforthestorageofnaphthaandpyrolysisgasoline.
Thestoragetanksforethyleneandpropylenearecryogenic.Theethylenetanksarekeptat103
AdditionalnaphthaforthenewcrackerisimportedviaashipthroughJohorPort.Thenaphthaisoff
loadedattheportandstoredintanksuntilitispiped1.5kmtothepetrochemicalcomplex.
Environmentalmanagement

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PursuanttorequirementsbyMalaysia'sDepartmentofEnvironment(DOE),Titanemployed
contractorstoprepareandsubmitQuantitativeRiskAnalysis(QRA)andEnvironmentalImpact
Assessments(EIA)studiesforitspetrochemicalactivities.
TheQRAidentifieshazardsandquantitativelydeterminestheriskposedtothelocalpopulation.
TheEIAisanassessmentoftheimpactofnewprojectsontheenvironment.Invariousstages,itis
subjecttoDOEapprovalandpubliccomments.
Titanhasacomprehensiveenvironmentalmanagementpolicycoveringairandwaterpollution,noise
pollution,disposalofgaseous,liquid,andsolidwastes,andlocalecology.Thisisachievedpartly
throughpollutionmonitoringandcontrolequipmentintheplantdesignandpartlythroughanemphasis
onpollutionmanagementandcontrolproceduresintrainingprovidedbythelicensors.
Titan'spetrochemicalcomplexcontainsawastewatertreatmentsystemthatprocessesabout75cu
m/dayofwater.Eachcrackerhasitsownwastetreatmentsystem.
Awetairoxidationunittreatsspentcausticbyoxidizingsulfitesandresidualhydrocarbon.Airfloatation
units,biotreatmentfacilities,andclarifierunitstreatspentcausticandplantwastewatertoMalaysia's
dischargestandards.Oncetherelevantwastematerialisremovedfromthewater,thewateris
dischargedintoanearbyriver.
Gaseousemissionsarecompletelycombustedinflarestacks.Drumsstorethescheduledwastes,
whicharesubsequentlytransportedtoKualitiAlamatBukitNenas,theonlygovernmentauthorizedunit
fortreatmentanddisposalofhazardouswastes.
Titanregularlyperformsair,water,noise,anddustsamplingatitspetrochemicalplantsandsubmitsthe
resultstoMalaysia'sDOEandthePasirGudanglocalauthority.
Businessstrategy

TomaintainitspositionastheleadingintegratedpetrochemicalsgroupinMalaysiaafterPhaseII,the
TitanGrouphasadoptedfiveprimarybusinessobjectives:

Expandproductioncapacityandimproveproductmix.Titanplanstocapturethefuture
growthinPEandPPdemandinMalaysiaandAsia.PhaseIIoftheexpansionproject
allowsTitantoproduceawiderrangeofproductsandgradesthatwillattracthigher
margins.

BeforethecompletionoftheLDPEplantinNovember1999,importsweretheonlymeansofsatisfying
thedomesticdemandforLDPE.
ThenewPPfacilitywillresultinhighermarginsasaresultoflesswasteproduction,expanded
capacity,abroaderproductmix,andthedevelopmentofhighergradeproducts.

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Titanbelievesitslocationgivesitacompetitiveedgeinpricing,timelydelivery,transportationcosts,
andtechnicalsupport.

Continueasanefficientandlowcostproducer.Thecompanyintendstomaintainits
positionasanefficientandlowcostproducerbyimplementingprojectsthatbenefit
economiesofscale.Forexample,PhaseIImorethandoublesthecomplex'scapacity
withoutthesameincreaseinoverheadcosts.
Strengthensalesandmarketingactivities.Titanwillcontinuetofocusonitsmarketing
effortstoincreasesalesvolumesinbothdomesticandexportmarkets.Inthedomestic
market,itintendstobetheleaderinproductqualityandcustomerservice.

Priceandqualitymainlydrivetheexportmarket,andTitanispoisedtointernationallycompeteinthose
twoareas.IthasbranchofficesinHongKongandSingaporeandrepresentativeofficesinBeijing,
Shanghai,andTokyo.
AnewPlasticTechnicalCenter,tobeoperationalinthesecondquarterof2000atacostofabout
RM8.6million,willhelpTitantoimproveitscustomerserviceandtechnicalsupportandplayakeyrole
inTitan'sfutureresearchanddevelopmentactivities.Titanplanstostaffthecenterwithabout20
technicians,whowillinitiallyfocusonproductdevelopment.
Finally,themarketinggroupisexaminingwaystousetheInternettomarketitsproducts.Titanisa
chartermemberofChemConnectInc.,anonlinetradingforumforchemicals.

Useadvancedandstandardizedtechnologiesinitspetrochemicalcomplex.Apartfrom
thevariousprocesstechnologiesusedinPhaseII,TitanisalsousingAspenTechnology
Inc.'soptimizationsoftware,theAsahiEngineeringCo.Ltd.,Tokyo,preventive
maintenancesystem,andSAPsoftwaretorunitspetrochemicalcomplex.

AlltheplantshaveAspenTech'sinformationmanagementsystem,InforPlus21,whichprovides
informationtothedatahistorianforfutureenhancedinstallations.Currently,Titanisimplementing
AspenTech'sadvancedcontrolswithdynamicmatrixcontrollers(DMC)andrealtimeoptimizationon
thefirstcracker.Titanplanstodothesameforthesecondcrackerafterimplementationiscompleteon
thefirstone.
AspenTechalsoprovidedtrainingsimulatorsfortrainingpersonneltooperatethesecondcrackerand
LDPEplants.Sincethesecondcracker'slayoutandequipmentnumberingsystemwerenearly
identicaltothatofthefirst,operatorscouldbetrainedonthefirstunitandeasilytransferredtothe
second.
ThecomplexusesopenYokogawaCentumCSastheplatformforallthecontrolsystems.Onecentral
controlcenteroperatesbothcrackers,theBTXplant,andcrackerutilitysystemseventhoughthe
BTX
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crackersare450mapart.
Theprimarycontrollersforthenewcrackerarelocatedinanewlyconstructedsatelliteinstrument
house,whichconnectstothecentralcontrolroomwithadualfiberopticcable.

Takeadvantageofshareholdersupport.InJune1998,TPC,TPE,andTPPenteredinto
a10yearagreementwiththeWestlakeGroupinNorthAmerica(foundedbytheChao
Groupin1985)formanagementandmarketingadviceandtechnicalassistance.

Undertheagreement,Westlakeregularlysendsexperiencedpersonneltorenderassistanceinproject
development,operationsmanagement,training,processimprovement,andequipmentdesign.

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