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Jurong Island Then

In the beginning, there was just sea. There came a team of island builders and marketeers. Working in unison, they successfully developed and sold these former plots of lands as valuable real estate for chemical business.

The Jurong Island amalgamation project is one of the key initiatives under the M2000 programme to develop a world-class chemical industry cluster. The Jurong Island project is implemented based on a total approach to industry development. The objective is to reduce capital investments and minimise operational costs through creating synergistic linkages, one of which is the concept of sharing facilities.

The Jurong Island project will amalgamate a group of seven small islands off the southwestern coast of Singapore into a single island. The island would house the petroleum and petrochemical industries by reclaiming the channels between them and extending into additional sea space. The seven southern islands are Pulau Merlimau, Pulau Ayer Chawan, Pulau Ayer Merbau, Pulau Seraya, Pulau Sakra, Pulau Pesek and Pulau Pesek Kecil. With an existing land area totaling a little less than 1,000 hectares, the intention is to create an additional 1,790 hectares of land through reclamation. This will form a land mass of about 2,790 hectares which will be available for industries.

Tiny islands become home to oil giants in the 1960s

In the 1960s, this group of seven small islands had been identified as the ideal location for heavy industries. It became home to several large oil refineries including Esso, Mobil and Singapore Refining Company located on Pulau Ayer Chawan, Pulau Pesek and Pulau Merlimau respectively. In 1984, the first petrochemical complex in Singapore was established on Pulau Ayer Merbau. The cracker in this complex is operated by Petrochemical Corporation of Singapore, a joint venture between Shell and a Japanese consortium led by Sumitomo Chemical. The downstream players in the complex include The Polyolefin Company, Phillips Petroleum, Ethylene Glycols Singapore, Denka, and Kureha Chemicals.

With these pioneers in place, it became logical that the surrounding islands, when amalgamated, would be suitable for the development of a petroleum and petrochemical hub. The physical clustering of related chemical industries provides strong opportunities for industry integration and other benefits arising from economies of scale.

In 1991, the government approved the amalgamation plan at an estimated total direct development cost of S$7 billion. This was a direct response to the identification of the chemical industry as a key growth sector, contributing significantly to the Singapore economy. The idea was to reclaim the land in phases to keep pace and to meet the projected demand of the industry. The original schedule for the final phase of the reclamation was year 2030. However, with increasing demand from these industries over the past two years, the reclamation has progressed ahead of schedule. The completion of Jurong Island is targeted for the year 2003.

Physical land reclamation began in 1995, and Jurong Island was officially opened in October 2000. From the 991-hectare land area of the original seven islets, Jurong Island currently has a total land area of more then 3,000 hectares and would have added about 200 additional hectares by the time reclamation is completed.

Jurong Island Now

Today, Jurong Island is home to over 88 leading petroleum, petrochemical, specialty chemical and supporting companies from around the world, including the top 50 Global companies like Air Products, Air Liquide, Akzo Nobel, Asahi Kasei, Dainippon Ink and Chemicals etc. Industry luminaries like BASF, BP, Celanese, ExxonMobil, DuPont, Mitsui Chemicals, Chevron Oronite, Shell and Sumitomo Chemical have also taken the opportunity by setting up factories there to reap the benefits of comprehensive infrastructure and production synergies from this unique cluster development for oil, petrochemical and specialty chemicals.

Shell being one the companies on Jurong Island mainly manufactures styrene monomer, propylene oxide, polyether polyols and propylene glycols. The applications of the above mentioned chemicals products will be further explained later in the report. We will be looking into how the production of its chemicals is linked to the production of other products which have widespread applications.

Today, Jurong Island. Tomorrow, the beacon of the chemical world.

Opening of Jurong Island Road Link

The following is an article on the vast improvement made by the chemical industry in Singapore over the years, especially in the oil business industry. DP Lee Hsien Loong also commented on the symbolism of Jurong Island to Singapore.

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DP Lee Hsien Loong 10 February 2000
Opening of Jurong Island Road Link

Singapore is a hub to many world-class chemical companies serving as a strategic base for their Asia-Pacific operations.

The chemical industry has been growing rapidly over the last few tears, performance in 2004 was encouraging with a 29% year-on-year increase in output at 8652.6 billion and a 46% increase in value-added, up to S$7.5 billion. With robust performance, the chemical industry’s share of manufacturing output rose from 26% in 2003 to over 28%, strengthening its position as the 2nd largest industry after electronics.

The cluster development strategy involves leveraging on Singapore’s largest petroleum refining base to produce key feedstocks for building downstream petrochemicals, speciality chemicals and fine chemicals in an integrated manner.

As manufacturing and services become more closely integrated, chemical companies are repositioning for growth, increasingly leveraging Singapore’s total business capabilities while stepping up market driven R & D and testing new technology.

Strategically located at the heart of Asia-Pacific, Singapore is one the largest refining centres in the world, with the presence of oil majors such as Exxonmobil, Shell and Caltex.

Singapore is well established as a total oil business centre, with activities encompassing petroleum refining, marketing and trading. Oil majors are also using Singapore as a base for their regional headquarters and research and development activities. More importantly, the petroleum industry, with a total of refining capacity of 1.33 million barrels per day, is the world’s third largest centre after Houston and Amsterdam.

“Today, Jurong Island has also become a symbol of national enterprise. Here, we conceived and built an integrated petrolchemical industry complex out of coral reefs and a scattering of small islands.”

Businesses of Shell Company

Shell, other than being known for producing styrene monomer, propylene oxide, propylene glycol, polyether polyols, it is also involved in investment programmes to develop its businesses and to enhance the company's profitability.

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During 2004, Shell Eastern Petroleum Ltd (SEPL) announced that it would progress a project to build a world scale ethylene cracker. Downstream plants will include ethylene oxide (EO) and monoethylene glycol (MEG) capacity. Polypropylene and phenol production units are also likely to be included. These plants will be located on Singapore’s Jurong Island.

At the same time SEPL said that it would expand output at its refinery which is located on Singapore’s Bukom Island. This will provide feedstock for the planned ethylene unit, which would also be built on Bukom Island. The ethylene unit will provide feedstock for the planned production facilities on Jurong Island. The project is being developed as collaboration between SEPL and the Singapore Economic Development Board and the planned production plants are scheduled to start up during 2009.

During the final quarter of 2006, SEPL broke ground for its petrochemical complex located at the Pulau Bukom refinery in Pulau Ular, Singapore. The complex, which is known as the Shell Eastern Petrochemical Complex, is due to become operational by the end of 2009 or early 2010.

The refinery on Pulau Bukom Island

1. Ethylene cracker contract

• At the end of 2005 a joint venture between Japan’s Toyo Engineering and ABB Lummus Global of the US announced that it had been awarded a contract to provide the basic design and engineering package (BDEP) for the SEPL ethylene cracker. The cracker will be located on Bukom Island. It is expected that the facility will have a capacity of between 1m and 1.3mtpa

2. Ethylene cracker technology

• The cracker will be based on propriety technology supplied by ABB Lummus Global. It will be integrated in Shell’s existing refinery on Bukom Island

3. Ethylene oxide (EO)/Monoethylene glycol (MEG) contract

• During January 2006 Foster Wheeler Energy, based in the UK, and Japan’s Mitsubishi Chemical Engineering were appointed to provide the basic design engineering package for the monoethylene glycol (MEG) unit. The unit is slated to have a capacity of 750,000tpa. The plant will be located on Singapore’s Jurong Island and is expected to become operational in 2009. Feedstock for the plant will be sourced from the new ethylene cracker

4. Technology for the monoethylene glycol plant

• The new MEG plant will use Shell's OMEGA technology which incorporates Shell's proprietary EO technology for the front-end ethylene oxide unit. Catalytic glycol production technology developed by Mitsubishi Chemical Corporation will allow for production of the final product


• The OMEGA process is said to require less ethylene feedstock per tonne of MEG than existing technologies. Other advantages are said to include lower energy and water consumption

5. Basic engineering for butadiene unit

• During the final quarter of 2006 US-based ABB Lummus Global announced that it had been awarded a contract from SEPL in relation to a 175,000tpa butadiene unit. The contract covers a licence and basic engineering of a grassroots facility. ABB added the SEPL is set to make a final investment decision early in 2007 following completion of basic engineering

6. Butadiene technology

• The butadiene unit will use proprietary technology from ABB Lummus Global/BASF. This technology utilises n-methylpyrrolidone as a solvent which results in high purity butadiene and low operating costs

7. Refinery upgrade contracts

• Foster Wheeler Asia Pacific Ltd was awarded a separate contract for the basic design engineering package to modify and upgrade Shell's Bukom refinery. These modifications form a key aspect of the overall project which allows the integration of the ethylene cracker complex to the refinery to capture the benefits of oil-chemicals integration

8. Ethylene implementation contract

• Following the final investment decision, SEPL awarded JV partners ABB Lummus Global and Toyo Engineering Corporation a contract for the implementation phase of the world-scale cracker. The partners will provide engineering, procurement and construction management services for the 800,000tpa ethylene plant

9. Background

• Both the cracker and the MEG plant are part of an overall Singapore investment programme and are in line with Shell's overall strategy to develop its upstream business, enhancing the profitability of its downstream business. The integrated refining and petrochemicals complex will maximise site and location benefits and contribute to the profitability of Shell's downstream business

Production of Styrene Monomer

Chemical formula: C8H8

Shell companies have over 40 years' experience in producing and supplying styrene monomer around the globe. Today, the Shell Group is the second largest producer of styrene monomer in the world and has a strong global manufacturing base. Shell companies are recognized as technology leaders in operating co-product SM/PO (styrene monomer/propylene oxide) plants and conventional styrene monomer plants.

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Styrene monomer is an aromatic hydrocarbon which, under normal conditions, is a clear, colourless, flammable liquid. The conventional method for producing styrene monomer is the alkylation of benzene with ethylene followed by dehydrogenation to produce styrene monomer. Also, it can be produced via the ‘SMPO’ process, which co-produces styrene monomer and propylene oxide via the oxidation of propylene by ethylbenzene hydroperoxide. An alternative would be producing it through the DOW process.

Process:

1. The energy needed for the reaction is supplied by superheated steam (at about 720 degree Celcius) that is injected into a vertically mounted fixed bed catalytic reactor with vaporized ethylbenzene.
   
2. The catalyst is iron oxide based and contains Cr2O3 and a potassium compound (KOH or K2CO3) which act as reaction promoters.


3. Typically, 2.5-3 kg steam are required for each kilogram of ethylbenzene to ensure sufficiently high temperatures throughout the reactor. The superheated steam supplies the necessary reaction temperature of 550-620 0C throughout the reactor.


4. Ethylbenzene conversion is typically 60-65%. Styrene selectivity is greater than 90%. The three significant byproducts are toluene, benzene, and hydrogen.


5. After the reaction, the products are cooled rapidly to prevent polymerization.


6. The product stream (containing styrene, toulene, benzene, and unreacted ethylbenzene) is fractionally condensed after the hydrogen is flashed from the stream.


7. The hydrogen from the reaction is used as fuel to heat the steam (boiler fuel).


8. After adding a polymerization inhibitor (usually a phenol), the styrene is vacuum distilled in a series of four columns (often times packed columns) to reach the required 99.8% purity.

Industrial Safety Precautions:

Styrene monomer can affect you when breathed and by passing through the skin. It is a flammable and reactive chemical thus being a fire and explosion hazard. Good work practices in the production of styrene monomer can help to reduce hazardous exposures.

• Workers whose clothing has been contaminated by styrene monomer should change into clean clothing promptly, not taking contaminated work clothes home as family members could be exposed.


• No eating, drinking and smoking in the place where styrene monomer is handled / processed / stored as the chemical itself can be swallowed.


• Styrene monomer must be stored to avoid contact with oxidizing agents and catalysts for vinyl polymerization such as peroxides, strong acids, and aluminium chlorides since violent reactions will occur.


• Workers should use only non sparking tools and equipment, especially when opening and closing containers of styrene monomer. Due to the fact that it is highly reactive and flammable, styrene monomer should be stored with an inhibitor to prevent explosive reactions.

Production of Propylene Oxide

Chemical formula: C3H6O

In the 1960s, Shell chemicals companies entered the propylene oxide (PO) sector with the acquisition of a PO plant in Carrington, UK. Over the next 40 years, Shell chemicals companies grew into one of the leading players in the PO and derivatives market. The strength of their SM/PO (styrene monomer/ propylene oxide) technology strongly contributed to the attainment of their position.

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Propylene oxide is a colourless, reactive liquid with an ether-like odour. It is used primarily as a building block for the manufacture of a versatile range of derivative products.

Process:

There are a number of known technologies to produce propylene oxide i.e HPPO process. While other processes exist, the Shell chemicals companies have derived a strong competitive advantage by using and continually developing their proprietary SM/PO technology, a process in which propylene (C3) and ethyl benzene (EB) are simultaneously converted into propylene oxide (PO) and styrene monomer (SM), respectively.

Industrial Safety Precautions:

• Propylene oxide is also flammable and reactive so storage and unloading areas must be specifically designed and monitored.
• DOW (SMPO technology is also known as the DOW production) offers technical and product stewardship support by way of periodic safe handling and storage reviews, and training.

Production of Propylene Glycols

Chemical formula: C3H8O2 (MPG) / C6H14O3 (DPG)

Shell companies entered the Asian market with propylene glycols (PG). With the addition of PG capacity in Singapore and as part of the CSPCL complex in China, Shell chemicals companies have grown to become a recognized player in PG.

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Propylene glycols is the collective name for monopropylene glycol (MPG), dipropylene glycol (DPG) and tripropylene glycol (TPG). Shell chemicals companies are only involved in the manufacture of MPG and DPG.

Process:

Propylene glycols are also derivatives of propylene oxide (PO), produced in a two-step process. The first step is the reaction of PO with water into a mixture of MPG and DPG and the second step is the distillation and purification of the mixture into its two separate components.

MPG is the largest volume propylene glycol. It is a colourless, viscous, odourless liquid. It is highly hygroscopic and miscible in all ratios with water, alcohols, esters, ketones and amines. It also has limited miscibility with halogenated hydrocarbons and is not miscible with aliphatic hydrocarbons. DPG is a colourless, hygroscopic liquid. It is miscible with water in any ratio and highly soluble in most organic solvents.

Industrial safety precautions:

• Though propylene glycols are not classified as flammable, they can burn. Hence in the process of producing propylene glycols, workers should remove all ignition sources such as flames (no smoking) and sparks.
• Strong oxidizing agents, strong acids, contact with water and moist temperatures should be avoided as well.
• Contaminated clothing should be air-dried in a well-ventilated area before laundering.
• When handling product in drums, workers should wear safety footwear and use proper handling equipment should.
• Tanks must be clean, dry and rust-free.
• Containers should be kept tightly closed when not in use to prevent accidental contact or inhalation of propylene glycols.

Production of Polyether Polyols

CARADOL polyether polyols are derived from propylene oxide. They are organic materials with two or more alcohol end-groups (OH) and sometimes with micrometer polymer particles present in suspension. CARADOL polyether polyols are also available in a wide range of molecular weights and it is this variety which gives rise to a wide range of processing and application possibilities.

Process:

Since CARADOL polyether polyols are derived from propylene oxide and they are produced by base or acid catalyzed polymerization of propylene oxide, the process is similar to that of propylene oxide whereby the SMPO technology is used.

Applications of Styrene Monomer

Styrene monomer is a large volume commodity chemical used in the production of plastics and rubbers for numerous applications. It is also used in the manufacture of polymers for a wide range of consumer and industrial applications. The current global styrene demand is about 25 million metric tons per year.

Did you know that styrene production is also a major contributor to methane emissions?

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The main application of styrene monomer is used in the production of polymers. Below are the different types of manufactured polymers and their applications.

1. Polystyrene (High impact polystyrene)

The most common solvent used for this reaction is 1, 2-dichloroethane (EDC). The preferred initiator is a mixture of boron trifluoride and water. It is prepared by incorporating 1.5% by weight boron trifluoride gas into the organic solvent (EDC) containing 280 ppm water. This solution is continuously prepared in a holding vessel and will then be injected into the reactor system to get the polystyrene product.

• Used in packaging, appliances and consumer goods. Examples are CD cases, drinking cups, food containers and refrigerator door liners

2. Expandable polystyrene

• Used in building, construction and packaging. Examples are lightweight foam, used in home insulation, packaging material, padding inside motorcycle crash helmets or car interiors, bridge construction or building film-set scenery

3. Unsaturated polyester resin

• Used in building, construction and transportation

4. Styrene butadiene emulsion polymers

• Used in adhesives and binders in carpet & paper production

5. Styrene acrylate emulsion polymers

• Used in adhesives, paints and coatings

Applications of Propylene Oxide

Propylene oxide or 1, 2-epoxy-propane (PO), is a very reactive substance and it is one of the most important chemical intermediates. It is a commodity chemical used in the manufacturing of products, ranging from antifreeze to cosmetics and to make highly versatile polyurethane raw materials which, in turn, are used in the manufacturing of thousands of everyday products. The worldwide demand for PO was approximately 14 billion pounds (6.3 million metric tons) in 2005. Approximately 88 percent of that volume was consumed in the manufacturing of three families of PO derivative products: polyols, propylene glycols (PG) and propylene glycol ethers (PGE).

1. Manufacture of Polyurethanes

• Polyurethanes are used to produce rigid foams for thermal insulation in the construction industry and flexible foams for mattresses, furniture upholstery and seat cushioning in automotive applications

2. Production of intermediate products

• PO is a basic chemical used as a building block in the production of intermediate products, which are found in everything from antifreeze to cosmetics

3. Flame retardants

4. Modified carbohydrates (starches)

5. Synthetic lubricants

6. Oil field drilling chemicals

7. Textile surfactants

Applications of Polyether Polyols

Polyether polyols is a product of propylene oxide. This shows us the widespread application a chemical can have. Propylene oxide itself has many uses such as flame retardants, textile surfactants and it also leads to the manufacture of polyether polyols which in turn leads to more applications.

1. Usage in urethane applications

• Adhesives and sealants, elastomers, molded foams and flexible foams

Examples:

--> The adhesive system that glues the glass into a car window frame. It gives the car its structural stability and forms a seamless seal between the metal and the glass.

--> The adhesive that bonds rubber scrap into tiles.

--> The micro-cellular moulded elastomer that covers the metal frame in a car steering wheel.

--> The non-foam electrometric sheets that dampen the sound and vibrations under rail tracks.

2. Usage in non-urethane applications

• Surfactants and oil demulsifiers

Applications of Propylene Glycols

Like polyether polyols, propylene glycols are also a product of propylene oxide.

1. Dust suppression

• Dust formation and the associated housekeeping issues, plus the danger of dust explosions, make dust suppression important in mining and cement grinding applications

2. Dyes and inks

• Propylene glycols are excellent solvents and compatibilisers for the many dyes, resins and inks used in modern high-speed printing presses

3. Lubricants


4. Natural Gas Dehydration

• When natural gas is recovered, its water content may need to be lowered to prevent water from condensing in pipelines and freezing or from forming hydrocarbon hydrates. Hydrates can foul instruments and reduce line capacity

5. Plasticizers

• A plasticizer is a molecule that is added to a polymer to modify its properties, making it easier to process and/or meet application requirements such as improved toughness or flexibility. Plasticizers function by internal solvation of the polymer chains

6. Surfactants

• “Surfactant” is a contraction of the words surface-active and agent. Surfactants function by changing the surface tension at the interface of mixtures, allowing non-miscible materials to either be dispersed into water or separated from water

Overview

Below's a brief overview of the various chemicals products produced and their applications.

Applications of Styrene Monomer:

• Used in the production of polystyrene and polymers
• Used in high impact polystyrene --> CD cases, drinks cups, food containers and refrigerator door liners
• Used in expandable polystyrene --> lightweight foam, used in home insulation, packaging material, padding inside motorcycle crash helmets or car interiors, bridge construction or building film-set scenery

Applications of Propylene Oxide:

• Used in production of polyether polyols (Polyurethanes)
• Used in production of propylene glycols (Polyurethanes)
• Used in flame retardants
• Used in modified carbohydrates (starches)
• Used in synthetic lubricants
• Used in oil field drilling chemicals
• Used in textile surfactants

Applications of Polyether Polyols:

• Used in polyurethane foams for applications in the automotive
• Used in furnishing and building industries
• Used in urethane applications --> rigid foam, flexible foam, coatings, adhesives, sealants
• Used in non-urethane applications --> surfactants and oil demulsifiers

Applications of Propylene Glycols:

• Used in production of unsaturated polyester resins --> used to make everyday items such as bath tubs, small boats and water/chemical tanks and pipes
• Used in cosmetics
• Used in paints and coatings
• Used in airplane de-icers/anti-icers
• Used in hydraulic fluids
• Used in antifreeze and industrial coolants

Conclusion

Recap!

Basically, we have covered

1. The history of Jurong Island
2. Jurong Island now
3. Introduction to Shell Company
4. Businesses of Shell Company
5. Products of Shell
6. Processes
7. How the production of its chemicals link to the production of other products which have wide-spread applications
8. Application to daily life

Jurong Island is an important industrial and chemical hub to Singapore. There are as much as 88 companies from all around the world situated on Jurong Island. These companies produce a wide range of products that are very useful to our daily lives. Shell is only one of the many companies on Jurong Island and yet through the above research we can see that the production of its chemicals such as styrene monomer, propylene oxide is linked to the production of other products which have wide-spread applications, therefore the different industries on Jurong Island are very vital to us!