Technical issues shut Japanese crackers, delay restarts

A series of technical issues forced Japanese cracker operators to shut their units or delay restarts in July, resulting in lower olefins output and higher spot demand.

Idemitsu Kosan shut its naphtha cracker in Tokuyama, Yamaguchi prefecture on 15 July, because of gas leakage at its complex. The cracker can produce up to 623,000 t/yr ethylene and 370,000 t/yr propylene. Associated downstream units at the Tokuyama site are likely still operating, resulting in spot demand for prompt ethylene cargoes in the Japanese market, according to market participants.

The restart date of the cracker remains unclear, with some market sources saying that the cracker could be on line again in first-half of August. But others said the cracker will be off line until end of August to coincide with Idemitsu Kosan's planned maintenance schedule.

Idemitsu Kosan originally planned to shut the Tokuyama-based cracker in September for a 50-day turnaround. The firm declined to comment on the turnaround schedule, citing that the cracker remains shut and it is unsure when it can resume operations.

Mitsui's cracker in Sakai, Osaka prefecture also encountered technical issues during its cracker restart. The producer has completed the turnaround, which took place in early July, but will need to procure equipment to address technical issues for the cracker start-up, market participants said. Mitsui's cracker has a nameplate capacity of 600,000 t/yr of ethylene and 280,000 t/yr of propylene.

Fellow producer Maruzen Petrochemical also delayed the restart of its cracker in the Chiba prefecture. The cracker was shut on 15 May and was supposed to restart by mid-July. The shutdown has been extended to the end ofJuly, according to market participants. The reason behind the extensions were unclear. Maruzen's Chiba cracker has a production capacity of 525,000 t/yr of ethylene and 335,000 t/yr of propylene.

Tighter supplies

Shutdown extensions and sudden outages at crackers have tightened olefins supplies in northeast Asia, with Chinese market participants reporting limited offers this week. Asian ethylene prices in the cfr northeast Asia market rose slightly this week to $860-880/t, up by $8/t from the last session, according to Argus' latest assessments on 24 July.

Japan experienced a heavy cracker turnaround season this year, with four crackers conducting scheduled maintenance in the first-half of 2024. Eneos' cracker in Kawasaki prefecture was shut from 5 March until mid-May. Tosoh's Yokkaichi cracker in Mie prefecture was also shut for maintenance from 4 March to the end of April. Keiyo Ethylene's cracker in Chiba prefecture went off line on 10 April for a 14-day planned maintenance. Mitsubishi Chemical's cracker in Kashima, Ibaraki prefecture was shut from May to June.

Total ethylene exports from Japan this year are expected to fall from the previous year because of heavy cracker turnarounds. Japan's ethylene exports were at 239,642t during January-May, down by 5,733t from the same period in 2023, according to GTT data. Imports were at 20,296t from January to May, up by 13,500t or almost tripling on the year.

By Nanami Oki, Brian Leonal and Toong Shien Lee