THE CHEMICAL INDUSTRY

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THE CHEMICAL INDUSTRY

• Revised from
• http//chemicalengineering.dal.ca/Files/2_-_The_Ch
  emical_Industry.ppt

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OUTLINE

• Structure of the Chemical Industry
• Raw Materials and Energy
• Base Chemicals
• Chemical Processes

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STRUCTURE OF THE CHEMICAL INDUSTRY

• Raw materials are converted into products for
  other industries and consumers.
• Basic raw materials can be divided into
• organic, and
• inorganic.
• Inorganic raw materials include
• air, water and
• minerals.
• Fossil fuels and biomass belong to the class of
  organic raw materials.

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Structure of the chemical industry

• About 85 of chemicals are produced from 20
  simple chemicals called base chemicals.
• Base chemicals produced from 10 raw materials.
• Base chemicals converted to 300 intermediates.
• Base chemicals and intermediates classified as
  bulk chemicals.
• About 30,000 consumer products are produced from
  intermediates.

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Structure of the chemical industry
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Where these chemicals go..

• 12 of the cost of a car
• polyurethane seat cushions
• neoprene hoses and belts
• airbags and nylon seat restraints
• 10 of the cost of a house
• including the cost of important insulation
• pipes
• electrical wiring
• 10 of what the average household consumer buys
  and uses every day
• food products
• clothing
• footwear
• health and personal care products
• household cleansers
• home entertainment equipment.

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From http//www.chem.tamu.edu/class/majors/chem47
0/Sulfuric_Acid-2008.PPT
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From http//www.chem.tamu.edu/class/majors/chem47
0/Sulfuric_Acid-2008.PPT
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Canadian Industry
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Consumer products from raw materials
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Structure of the chemical industry

• Coal, oil and natural gas (NG) are the primary
  raw materials for production of most bulk
  chemicals.
• Each stage adds value
• Relative value
• Crude oil 1
• Fuel 2
• Typical petrochemical 10
• Typical consumer product 50

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Overview of the petrochemical industry
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Structure of the chemical industry

• First step in petrochemical industry is
  conversion of raw materials into base chemicals.
• Synthesis gas (H2 and CO) ?through steam
  reforming of NG ? ammonia or methanol.
• Lower alkenes through steam cracking of ethane or
  naphtha ethene, propene, butadiene.
• Aromatics through steam cracking of ethane or
  naphtha or the catalytic reforming process
  benzene, toluene, xylenes (BTX).

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Structure of the chemical industry

• The second step involves a variety of chemical
  processes often aimed at introducing various
  hetero-atoms (O, Cl, S etc.) into the molecule.
• This leads to formation of intermediates such as
  acetic acid, formaldehyde, acetaldehyde and
  monomers like acrylonitrile, terephthalic acid
  etc.
• The third step yields consumer products.
• The chemical industry can be conveniently divided
  into 7 sectors.

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World chemical market (1989)
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World chemical industry

• World output 2.7 trillion
• Americas 34
• Asia/Pacific/Africa 32
• Europe 34
• In 2000, there were 1,200 establishments
  operating in Canada.
• They employed approximately 72,500 employees.

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• In the USA, 70,000 chemical products in 12,000
  plants, 95 in batch operations.
• Top five organic chemicals ethylene, propylene,
  ethylene dichloride, methyl-tert-butyl-ether
  (MTBE), and vinyl chloride.
• Top inorganic chemicals nitrogen, oxygen,
  chlorine, and sodium hydroxide.

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USA Petroleum IndustryUSA has 163 operating
refineries and 15.6 million barrels per day
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USA Chemicals Industry
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RAW MATERIALS AND ENERGY

• Raw materials and energy are closely related.
• Indeed, the main raw materials for the chemical
  industry are fossil fuels.
• These are also the most important sources of
  energy.
• Major energy source is oil (40), Coal ( 26),
  then NG ( 21).
• But reserves show a different picture!

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Total world energy consumption
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Fossil fuel reserves (reserves/production) for
1997
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Petrochemical share of world oil
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Energy and the chemical industry

• A lot of energy is used in the chemical industry
  ( same order as used for feedstock)
• About 8 of crude oil demand is used as raw
  material in the chemical industry the balance is
  used for fuel production.
• Fuels for direct heaters and furnaces
• often same as raw material, e.g. in steam
  reforming of NG, the NG is used for both
  feedstock and fuel.
• Fuel oil (a product of distillation) is often
  used to preheat feed to the crude oil
  fractionator.

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Energy and the chemical industry

• Steam
• Usually most important utility system.
• Used for process heating, a reactant, in
  distillation.
• It is used saturated, wet or superheated.
• Steam used is replaced by treated make-up water.
• Steam used at 3 pressures levels
• Operating Conditions Saturation
• Pressure (bar) Temp (K) Temp (K)
• HP 40 683 523
• MP 10 493 453
• LP 3 463 407

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Steam/power generation
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Energy and the chemical industry

• Electricity
• Can be generated in-plant or purchased from
  utility.
• Reduction of energy costs by generation of power
  on-site with steam turbines and process heating
  with exhaust gases.
• Often economical to drive large compressors with
  steam.
• Co-generation (electricity and local/district
  heating).
• Integrated coal gasification combined cycle
  (ICGCC) power generation (? is 41-43 vs 34-35
  for PF / steam turbine).

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BASE CHEMICALS

• Most important base chemicals are the lower
  alkenes (ethene, propene and butadiene), the
  aromatics (BTX), NH3 and CH3OH.
• Syngas (a mixture of H2 CO) can be used as a
  base chemical feedstock (e.g. Fischer-Tropsch).
• Most chemicals can be produced directly or
  indirectly from these building blocks.
• Feedstock depends on location production unit.

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Lower Alkenes from oil
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Lower Alkenes from NG
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Aromatics production
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Ammonia and methanol production
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Business-cash flowchart
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Petroleum Industry Technologies
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Chemicals Industry Technologies
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Levels of development
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Space and time scales