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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

© Repsol Polímeros, Sines, November 2018. 3


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

© Repsol Polímeros, Sines, November 2018. 4


Site and surrounding area overview
2

© Repsol Polímeros, Sines, November 2018. 5


2. Site and surrounding area overview
Site location

Repsol
Polímeros

Sines

Lisbon
150 km Petrochemical
Harbour
Sines

© Repsol Polímeros, Sines, November2018. 6


2. Site and surrounding area overview
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

© Repsol Polímeros, Sines, November 2018.


2. Site and surrounding area overview
Petrochemical port facilities general view

Harbour
facilities

© Repsol Polímeros, Sines, November 2018.


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

© Repsol Polímeros, Sines, November 2018. 11


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

© Repsol Polímeros, Sines, November 2018.


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

© Repsol Polímeros, Sines, November 2018.


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)

© Repsol Polímeros, Sines, November 2018.


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

© Repsol Polímeros, Sines, November 2018.


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

© Repsol Polímeros, Sines, November 2018.


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

© Repsol Polímeros, Sines, November 2018.


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
© Repsol Polímeros, Sines, November 2018.
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

© Repsol Polímeros, Sines, November 2018.


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

© Repsol Polímeros, Sines, November 2018.


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

© Repsol Polímeros, Sines, November 2018.


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 ~
© Repsol Polímeros, Sines, November 2018.
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

© Repsol Polímeros, Sines, November 2018.


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

© Repsol Polímeros, Sines, November 2018.


Site main figures
4

© Repsol Polímeros, Sines, November 2018. 25


4. Site main figures
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

© Repsol Polímeros, Sines, November 2018. 26


4. Site main figures
Certificates

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


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

© Repsol Polímeros, Sines, November 2018. 27


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 Polímeros, Sines, November 2018. 28


4. Site main figures
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 Polímeros, Sines, November 2018. 29
4. Site main figures
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
© Repsol Polímeros, Sines, November 2018. 30
Reliability Improvement
5

© Repsol Polímeros, Sines, November 2018. 31


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

© Repsol Polímeros, Sines, November 2018. 32


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

© Repsol Polímeros, Sines, November 2018. 33


Polyolefins products
6

© Repsol Polímeros, Sines, November 2018. 34


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

© Repsol Polímeros, Sines, November 2018.


6. Sines polyethylene grades
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
© Repsol Polímeros, Sines, November 2018.
6. Sines polyethylene grades
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)

© Repsol Polímeros, Sines, November 2018.


Olefins other products
7

© Repsol Polímeros, Sines, November 2018. 38


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.

© Repsol Polímeros, Sines, November 2018.


Sines Olefins and Polyolefins Markets
8

© Repsol Polímeros, Sines, November 2018. 40


8. Markets
2013-2017 worldwide (Olefins + Polyolefins)

1% 84%
EUA & Europa
Canadá
3%
Ásia &
Extremo Oriente

5%
África &
7% Médio Oriente
América
Latina

© Repsol Polímeros, Sines, November 2018.


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

© Repsol Polímeros, Sines, November 2018. 43


9. Significant investments in recent years

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€

© Repsol Polímeros, Sines, November 2018. 44


9. Significant investments in recent years

70
[M€]

60

50

40

30

20

10

0
2012 2013 2014 2015 2016 2017 2018

Total 80M€ between site turnarounds

© Repsol Polímeros, Sines, November 2018. 45


9. Significant investments in recent years

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

© Repsol Polímeros, Sines, November 2018. 46


Ethylene worldwide market outlook
10

© Repsol Polímeros, Sines, November 2018. 47


10. Ethylene market outlook

© Repsol Polímeros, Sines, November 2018. 48


10. Ethylene market outlook

© Repsol Polímeros, Sines, November 2018. 49


What’s next?
11

© Repsol Polímeros, Sines, November 2018. 50


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

© Repsol Polímeros, Sines, November 2018. 51


Thank you

© © Repsol Polímeros, Sines, November 2018.