Petrochemical Industry in EGYPT

Polyethylene terephthalate
PET is produced by the step-growth polymerization of ethylene
glycol and terephthalic acid.

Ethylene glycol is a colourless liquid obtained from ethylene,

Terephthalic acid is a crystalline solid obtained from xylene.

When heated together under the influence of chemical catalysts,

ethylene glycol and terephthalic acid produce PET in the form of
a molten, viscous mass that can be spun directly to fibres or
solidified for later processing as a plastic. Water is also
produced as a by-product.

The presence of the large benzene rings in the repeating units

gives the polymer notable stiffness and strength).
 Polyethylene terephthalate
PET exists both as an amorphous (transparent) and a semi-crystalline (opaque and
white) thermoplastic, and can be made into either a resin, film or fibre.

In its semicrystalline form, PET is made into a high-strength textile fibre marketed
under such trademarked names as Dacron.

Molten PET can be blow-molded into transparent containers of high strength and
rigidity that are also virtually impermeable to gas and liquid. In this form, PET has
become widely used in carbonated-beverage bottles and in jars for food processed at
low temperatures.
The low softening temperature of PET—approximately 70 °C prevents it from being
used as a container for hot-filled foods.

PET is the most widely recycled plastic. PET bottles and containers are commonly
melted down and spun into fibres for fibrefill or carpets. When collected in a suitably
pure state, PET can be recycled into its original uses, and by breaking the polymer
down into its chemical precursors for resynthesizing into PET.
The recycling code number for PET is #1.
 1. Egyptian Indian Polyester Company (EIPET)
Website: http://eipet.com/

Egyptian Indian Polyester Company "EIPET", an Egyptian Joint Stock Company between
Dhunseri Petrochemical and Tea Limited (DPTL) a company incorporated in India, and the
Egyptian Petrochemical Holding Company.

Located: Al-Ain Al-Sokhna - Suez.

Capacity: The plant capacity is 1200 MT per day (420,000 MT per annum) based on
technology from Oerlikon Barmag, Germany.

Product:
The PET (polyester) resin is used for manufacturing of food grade material and is used as
raw material by bottle manufacturers for packaging of Mineral water, carbonated soft
drinks such as Edible oils, Pharmaceutical products, Shampoos & Toiletries.

FEEDSTOCK:
PTA (Purified Terephthalic Acid)
MEG (Mono Ethylene Glycol)

PRODUCT: Polyester– PET

CHEMICAL REACTION:

Control Room
Plant facilities
Pipelines and Valves:
Pump, strainer, Flanges/valves, pressure gauges, utility pipelines and
check valve:
Plant over view
The product is in granular form and packed in 1000 kg jumbo bags.

Storage site
Storage tanks and Silos
Laboratory for quality check
About 20% of the produce is used locally and the remaining amount
is exported to European and North American markets.
 Polyethylene
The linear versions are known as:
high-density polyethylene(HDPE) and
ultrahigh molecular weight polyethylene (UHMWPE).

The linear form of polyethylene, high-density polyethylene (HDPE).

Branched versions are known as
low-density polyethylene (LDPE) or
linear low-density polyethylene (LLDPE);

The branched form of polyethylene, low-density polyethylene (LDPE).

 2. Sidi Kerir Petrochemicals Company (Sidpec)
Website: http://www.sidpec.com/

Sidi Kerir Petrochemicals Company (Sidpec) is an Egyptian Joint Stock company. Sidpec
is located at the Petrochemicals Complex, Amreya, Km 36 Alexandria – Cairo Desert
Road.

FEEDSTOCK:
Ethane/ Propane Gas Mixture from the Egyptian Natural Gas Company (GASCO)

PRODUCT:
1. Ethylene 300 KTA (polymer grade ethylene purity 99.95 wt. %)
2. Polyethylene ( HDPE & LLPE ) 225 KTA
3. LPG 50 KTA
4. Butene –1 10 KTA

The trade name of SIDPEC polymers is named "Egyptene" includes linear low density
polyethylene (LLDPE) and high density polyethylene (HDPE).
CHEMICAL REACTION:

1. Dehydration of ethane:

CH3-CH3 → CH2=CH2 + H2 (by steam cracking)

2. Polymerization of ethylene:

n CH2 = CH2 → [-CH2-CH2-]n

What is meant by : Train from the chemical engineering point of view?
Ethylene Plant

Plant Capacity: 300 KT/ year

Feed Stock: Ethane / propane mixture
Technology & Know How: ABB Lummus (USA)
Start up date: August 2000
Applications:
* Production of High density and Linear low density polyethylene.
* Production of poly vinyl chloride (PVC)
Plant Capacity: 225 KT/ year
Polyethylene Plant
Feed Stock : Ethylene + Hydrogen
Technology & License: bp Chemicals (Ineos)
Start up date: October 2000

Butene-1 is produced by a catalytic dimerization reaction of ethylene

Formula : CH2=CH-CH2-CH3
Applications:
- Used as a co-monomer in polyethylene production to control density.
- Used as a monomer in butadiene and poly butadiene production (synthetic rubber ).
 Utilities

What is meant by: Utilites?

Why are utilities used in the
petrochemical plants?
 How to Quality Control?
Different laboratories sections to quality control all production processes. The laboratories
apply standard test methods and most advanced equipment to achieve high accuracy and
precision e.g. (UV, FTIR, ICPS, IC, GC…etc.).

Responsibilities of these laboratories include:

** Analysis of ethylene, LPG and steam in all production stages.
** Analysis of water starting from raw water and different purification stages as pH, Cond.,
Turb., SO4, PO4, Fe, Silica, etc.
** Environmental analysis to assess the effectiveness of waste water treatment unit and
flow gas analysis of boilers stacks and crackers stacks to comply with Egyptian
environmental law No.4 for 1994. Analysis includes Heavy metals, COD, BOD, Oil, CO,
NOx, SOx, etc.
** laboratory periodically participates in proficiency test programs (?? What is this) to
assure the quality of test and calibration results.
** The lab has been accredited by Egyptian Accreditation Council (EGAC) in compliance with
the requirement of ISO /IEC 17025:2005 since 2009, in the field of determination of pH value
for water. (why do you think this is important?)
Plant over view

Spherical Storage tanks

what are the different shapes of storage tanks used for ?

Spherical
Cylindrical
Silos
Sidpec produce a high-density polyethylene grade with a broad molecular weight
distribution. This grade has been especially developed for the production of very
thin film with high tensile strength and stiffness.

Applications:
• Strong thin film
• Carrier bag
• Grocery sacks

characteristics:
1. Excellent drawdown ability
2. Good extrudability
3. High tensile strength
4. High stiffness.
SIDPEC produce Linear Low Density Polyethylene (LLDPE) copolymer with
butene as co-monomer, that contains antioxidant, slip and antiblock additives.
It gives film of high slip, which is easily separable.

Applications:
• Agriculture films, stretch film, liners.
• Produce bags, Carrier bags, Refuse sacks, Heavy duty sacks

Characteristics:
1. Easier Sealing
2. High tensile strength
3. Higher puncture resistance
Blow molding

Sidpec produce medium molecular weight polyetheylene copolymer grade with a

broad molecular weight distribution, which offers excellent processing
properties for use in a range of blow moulding applications.

Characteristics:
1. Excellent Processing
2. Good Rigidity
3. Good Environmental Stress-cracking resistance
4. Medium impact strength.

Applications:
• Chemicals
• Household products
• Oils and food stuffs
• Blow moulded containers up to 30 liters for packaging
 SIDPEC produce high-
density polyethylene
grade with a narrow
molecular weight
distribution, suitable for a
wide range of injection
moulding applications.

Characteristics:
1. Easy Processing
2. High rigidity
3. Good impact strength

Applications:
• Crates
• Boxes
• Seats
• Large dustbins
• General purpose heavy-duty articles
SIDPEC produce UV stabilized medium density-polyethylene co-polymer grade with a
narrow molecular weight distribution.

Applications:
• Rotational moulded items: tanks, containers
• Injection moulded technical parts and closures

Characterization:
1. Excellent internal and external surface finish
2. Excellent Process Ability
3. Impact Strength
4. High Stiffness
 3. Ethylene and Ethylene Derivatives Company (ETHYDCO)
Website: https://www.ethydco-eg.com/

The complex aims at producing Ethylene and polyethylene to maximize the value added
to Ethane/Propane mixture produced by The Western Desert Gas Complex in
Alexandria.
Product will be used as a feedstock for many intermediate petrochemical industries,
such as PE, Styrene and PVC, synthetic rubber, pipes, electric apparatus, vehicles, and
medical utilities, etc. while surplus is to be exported.

ETHYDCO is a manufacturer and leading provider of value creating Plastics &

Rubber products (Linear Low & High Density Polyethylene, Butadiene, Low Cis
and Solution Styrene Butadiene Synthetic Rubber).

FEEDSTOCK: Ethane

PRODUCT:
460 Thousand Tons/Year Ethylene.
400 Thousand Tons/Year Poly Ethylene
CHEMICAL REACTION:

1. Dehydration of ethane: CH3-CH3 → CH2=CH2 + H2 (by steam cracking)

2. Polymerization of ethylene: n CH2 = CH2 → [-CH2-CH2-]n

They take the ethane/propane mixture (from Gasco) and convert it into Ethylene.
Ethylene
Capacity : 460 KTA
Licensor: Lummus - USA
Polyethylene Plant
Butadiene Capacity: 400 KTA (2x200 KTA)
Capacity : 20 KTA Licensor : Univation – USA
Licensor: Lummus - USA Technology: UNIPOL PE
Ethylene is polymerized into Polyethylene.
http://www.univation.com/unipol.animation.html
Polyethylene is then conditioned to be shipped to the customers.
 How are PE processed and using?

From film extrusion to injection molding, the design and the size of the
machines may differ quite a lot but it always follow the general principle
described above
End products manufactured using ETHYDCO polyethylene
ETHYDCO manufactures Solution polymerized styrene-butadiene rubber ―SSBR‖
and Low-Cis polybutadiene Rubber ―LCBR‖ which is the raw material for highly
specified tyre components used in the fabrication of high performance tyres.

ETHYDCO use VERSALIS technology, The Versalis s-SBR technology enables the
production of many grades of Dry and Oil Extended polymers through batch or
continuous polymerization. Cyclopentane, cyclohexane or n-Hexane or blend, can
be used as solvent; small quantity of volatile organic compounds (solvent) enter the
finishing section (low release during extrusion).

Tuning the polymer composition (% of styrene) and polymer microstructure (% of

vinyl group) (linear radial or branched different macrostructures ) is possible to
obtain products, in the field of tyre application, characterized by:
• good processability;
• good ice/snow grip;
• good rolling resistance;
• grades with optimum compromise between rolling resistance and grip.
Butadiene Derivatives Plant
Capacity : 36 KTA
Licensor : Versalis – Italy
 Zero Liquid Discharge plant

Why use Zero Liquid discharge?

Does petrochemicals companies care about profit or environment?
Any questions???

15 minutes Break
PolyVinyl Chloride

Windows & Door profiles

Pressure pipes
Flexible films and sheets
Footwear
 4. Egyptian Petrochemicals Company (EPC)
Website: http://www.egy-petrochem.com/

Egyptian Petrochemicals Company (EPC) was established in 1981 as a public Sector

Company totally owned by the petroleum sector for purposes of production, trading
selling, importing, and exporting of petrochemical materials.

Location: EPC complex, located at Petrochemicals Complex, Amreya, Km 36 Alexandria –

Cairo Desert Road. It aims at producing PVC using suspension polymerization.

FEEDSTOCK:
1. Raw Salt
2. Ethylene purchased from Sidpec.

PRODUCT:
1. PVC Resin 80 k tone
2. PVC Compounds 30 k tone
3. Caustic Soda (liquid, Flakes) 72 k tone
4. Sodium Hypochlorite (apploication : Bleaching agent, Chemicals industry )
Ethylene dichloride (EDC) can be produced either by substitution chlorination
or by Oxychlorination.
Ethylene dichloride (EDC) is the raw material for the production of PVC
(polyvinylchloride).

Substitution chlorination
1.Electrolysis
2NaCl + 2H2O → CL2 + 2NaOH + H2

2. Substitution Chlorination
CH2=CH2 + CL2 → ClCH2-CH2Cl Ethylene dichloride (EDC)

Oxychlorination:
The oxychlorination reaction occurs in a fluidized bed reactor of a catalyst with
a size range from 40 – 125 microns

CH2=CH2 + 2HCl + ½ O2 → ClCH2-CH2Cl + H2O

Ethylene dichloride (EDC)
Thermal cracking (pyrolysis)
ClCH2-CH2Cl → CH2=CHCl + HCl
Ethylene dichloride (EDC)

Polymerization
n CH2= CHCl → *-CH2-CHCl-]n Polyvinyl chloride (PVC)
Vinyl chloride monomer production
from EDC (ethylene dichloride)

EDC

T = 80 c
PREHEATER
EDC,VCM,HCL CRACKER
EDC TANK PUMP
80 C
WATER COOLER

WATER COOLER
HCL CONDENSER 500 c
EDC,VCM,HCL
L,90 c

90 C
RECEIVER TANK QUNCHER

L,90c,20 kg/cm2
REACH STREAM VCM L,90c,20 kg/cm2
REACH STREAM HCL L,90c,20 kg/cm2
 Furnace for pyrolysis
Reactor
Chemical Laboratories
Polypropylene
 5. Egyptian propylene and poly propylene company (EPPC)

Egyptian Propylene & Polypropylene Company (EPP) commenced production in 2011 to

produce 400,000 T/Y Propylene and Poly Propylene.

Location: EPPC is located in El Gameel industrial zone – Port Said.

FEEDSTOCK: 430 kta of fresh propane from Untied Gas derivatives company UGDC.

PRODUCT: Poly propylene homopolymer and copolymer with ethylene 400 KTA
LyondellBasell

Technology Used:
Propylene process technology
Uhde's Star process technology is used for the dehydrogenation of propane to propylene.

Polypropylene (PP) process technology

Germany's Basell provided its Spheripol process technology for the 350,000tpa PP plant,
which produces "a wide range of high-quality PP pellets".
Uses:
Propylene and Poly Propylene have a wide range of usage in the production of plastics,
packaging and rugs. The PP pellets can be used in textiles, rigid flexible packaging,
consumer goods and automotive.
Products from EPPC's plant meet domestic and export demands.

CHEMICAL REACTION:

1. Dehydration of propane:

CH3-CH2-CH3 → CH3-CH=CH2 + H2 (by steam cracking)

2. Polymerization of propylene:

n CH3-CH = CH2 →

3. Copolymerization of propylene- ethylene:

Propylene process technology
Star process reformer
for the dehydrogenation of
propane to propylene
 Polypropylene (PP) process technology

As shown in the figure below, the Spheripol process comprises three steps:
1. Catalyst and raw material feeding,
2. Polymerization
3. Finishing.

When the catalyst and propylene are

injected into the baby loop reactor,
prepolymers are created. The
prepolymers are injected into the loop
reactor and then homo PP and random
pp are produced through bulk
polymerization.

In the gas phase reactor, polypropylene

and ethylene are fluidized and vaporized,
EPR (Ethylene-Propylene Rubber) is
created, and thus copolymers can be
produced.
In the finishing step, pellet type Animation link:
polypropylene products can be produced http://www.polymirae.com/en/product/popup_spheripol.php

through drying and extrusion processes.

Polystyrene
 6. Egyptian Styrene & Polystyrene Production Company
(ESTYRENICS)
Website: https://www.estyrenics.com/

The Project aims at producing Styrene to satisfy the feed requirements of the
Polystyrene plant and export the Styrene surplus. The plant is located in Al-Dekheila
Port- Alexandria.

Uses: The polystyrene produced is set to be feedstock for the production of packaging,
vehicle equipment, building materials and other important industries.

FEEDSTOCK: 80 KTA Ethylene from Ethydco

Benzene

PRODUCT:
200 KTA Poly-Styrene
300 KTA Styrene

Technology:
Estyrenics use INEOS/Lummus technology for the manufacture of High Impact
Polystyrene (HIPS) and General Purpose Polystyrene (GPPS).
CHEMICAL REACTION:
1. Production of ethyl benzene from benzene:

2. Dehydrogenation of ethyl benzene to styrene:

Ethylbenzene vapour is mixed with excess steam and passed over heated iron(lll)
oxide. Other metal oxides used as the catalyst including those of magnesium,
chromium(III) and zinc, usually coated on carbon or alumina. It is dehydrogenated:

The steam reduces 'coking' (the formation of soot on the catalyst from the
decomposition of ethylbenzene at the high temperatures used).

3. Polymerization of styrene:
3. Polymerization of styrene:
 7. Egyptian Linear Alkyl Benzene Company (ELAB)
Egyptian Linear Alkyl Benzene Company (ELAB) is an Egyptian Joint Stock company,
located in Alexandria, Egypt.
Egyptian Linear Alkyl Benzene Company (ELAB) was implemented on November 2003
to meet local market demand for Linear Alkyl Benzene whereas surplus is dedicated for
export.

Uses: Alkyl Benzene is used in the manufacture of liquid and powder detergents after
sulfonation to produce linear alkylbenzene sulfonate (LAS) for Detergents production.

FEEDSTOCK:
Benzol from reformate, Kerosene and Kerosene Jet A1, and Hydrogen.

PRODUCT:
1. LAB 100 KTA
2. HAB 5 KTA
CHEMICAL REACTION:

1. The linear paraffin (kerosene) is dehydrogenated to linear olefins

2. The most common synthetic anionic surfactants are based on the straight chain
alkylbenzene sulfonates.
Benzene, in slight excess, is mixed with an alkene or chloroalkane in the presence of an
acid catalyst, usually a solid zeolite (ion exchange), aluminium chloride (AlCl3) or
hydrofluoric acid (HF), to produce an alkylbenzene.

For example:
3. The alkylbenzene varies in average molecular mass, depending upon the starting
materials and catalyst used and is often a mixture in which the length of the alkyl side
chain varies between 10 and 14 carbon atoms.

If alkylbenzene included branches in the side chains it will biodegrade very slowly and
lead to foaming in rivers and sewage plants. By law, in most countries today, the
surfactant must have side chains which are not branched so they degrade more rapidly.

The alkylate is sulfonated using an air/sulfur trioxide mixture, and the resulting sulfonic
acid is then neutralised with an aqueous solution of sodium hydroxide (often in situ),
for example:
What happen when we dehydrogenate paraffin's (remove hydrogen)?

Do you know an example of a paraffin that you use regularly?

 8. Amreya Petroleum Refining Company (APRC)
LAB Unit is included in Amreya Petroleum Refining Company which is an Egyptian
Public Sector Company established in 1984. It is located at Amreya, km-17, Alexandria -
Cairo Desert Road.

FEEDSTOCK:
- Kerosene : From Amreya Petroleum Refining Co.
- Jet fuel A : From Amreya Petroleum Refining Co.
- Benzene : From Amreya Petroleum Refining Co.

PRODUCT:
- Linear Alkyl Benzene (LAB) 50 K tone
- Heavy Alkyl Benzene (HAB) 3 k tone
 9. EMETHANEX
EMETHANEX is an Egyptian joint venture with Canadian Methanex Corporation; the
global leader in Methanol industry distribution and marketing. E-Methanex is
located in Damietta on Mediterranean Sea in Egypt.

EMETHANEX is a foundation stone for a number of blooming industries like the

manufacturing of solvents, paint, adhesives, and medical supplies.

The project has a plant capacity of 1300 Million T/Y Methanol and a total investment
cost of 1022 Million USD. The plant commenced in 2011 with high performance
production rates.

FEEDSTOCK: Natural Gas from GASCO’s Metric Station.

PRODUCT: Methanol 1300 KTA

MeOH Applications:
1. Chemical Intermediate and Fuel.
2. Fuel Cell Applications.
3. Bio-Diesel Production.
4. Miscellaneous Uses of Methanol.
 10. Misr Fertilizers Production Company (MOPCO)
MOPCO was established on July 1998 in Damietta free zone to produce Ammonia and
Urea.

The company is committed to protect and develop the environment by maintaining

the highest international codes and standards of environmental protection. Why ??

It is considered as one of the largest fertilizer plants in Egypt and Middle East. Moving
forward and based on international gas prices, MOPCO Expanded to produce 1.4
Million T/Y of Urea. The overall total investment cost reached 1800 Million USD in
which national capital constituted 70% while Arab and foreign capitals 30%.

FEEDSTOCK: Natural gas from the Egyptian Natural Gas Company (GASCO)

PRODUCT:
1. Ammonia Plant.
2. Urea Plant.
1. Primary steam reforming converts methane and steam to synthesis gas, a mixture of
carbon monoxide and hydrogen:

2. The shift reaction

This process converts carbon monoxide to carbon dioxide, while generating more
hydrogen.

3. The manufacture of ammonia (The Haber Process)

Future Plan:
1.Gas to Olefins Complex (GTO)
This project targets optimizing the Egyptian natural gas usage, satisfying the market’s
needs of Olefin (Ethylene & Propylene) and Poly-olefin (Polyethylene & Polypropylene),
and exporting the surplus.
The project will use the state-of-the-art technology to convert the lean natural gas
(mainly C1) into methanol, then convert methanol into olefins (ethylene and/or
propylene).

2. Aromatics Complex
This project aims at producing (para-xylene & Benzene) to serve several downstream
petrochemical projects (PTA, PET, PS ... etc) in Egypt, by utilizing Naphtha obtain from
existing refineries in Suez. The surplus of this production will be exported.
3. Petrochemicals Downstream Clusters

Developing world-class industrial downstream clusters based on the basic

petrochemical products that are produced.
FORTHCOMING OPPORTUNITIES in EGYPT

1.Bio-Ethanol from Sugar Beet Molasses

The project aims to produce Bio-Ethanol from Sugar Beet Molasses to be blended with
Gasoline providing a clean alternative energy resource. Ethanol as well shall be used as a
feedstock for a number of petrochemical products to maximize value added.
Location: Motobus – Kafr Al-Sheikh Governorate (ECHEM Land)
Expected start up date: 2018

2. Bio-Ethanol from Rice Straw

The project aims to produce Bio Ethanol from Rice Straw and agricultural wastes to be
blended with Gasoline providing a clean alternative energy resource. Ethanol as well shall
be used as a feedstock for a number of petrochemical products to maximize value added.
Location: Motobus – Kafr Al-Sheikh Governorate (ECHEM Land)
Expected start up date: 2018

3. Propylene & Propylene Derivatives

The project aims to produce Propylene & Derivatives using GASCO’s Propane as a
feedstock to maximize value added. Production shall serve local market needs and export
surplus.
Location: Alexandria Governorate (EPC Land)
Expected start up date: 2019
4. Formaldehyde & Derivatives
The project aims to produce Formaldehyde & Derivatives using EMETHANEX’s
Methanol as a feedstock to maximize value added. Production shall serve local market
needs and export surplus.
Location: Motobus – Kafr Al-Sheikh Governorate (ECHEM Land)
Expected start up date: 2018
Any questions???