THE CHEMICAL INDUSTRY Revised from: http://chemicalengineering.dal.ca/Files/2_-_The_Chemical_Industry.ppt

CHEE 2404: Industrial Chemistry OUTLINE Structure of the Chemical Industry Raw Materials and Energy Base Chemicals Chemical Processes CHEE 2404: Industrial Chemistry

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. CHEE 2404: Industrial Chemistry

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. CHEE 2404: Industrial Chemistry

Structure of the chemical industry CHEE 2404: Industrial Chemistry

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. CHEE 2404: Industrial Chemistry

CHEE 2404: Industrial Chemistry

CHEE 2404: Industrial Chemistry From: http://www.chem.tamu.edu/class/majors/chem470/Sulfuric_Acid-2008.PPT CHEE 2404: Industrial Chemistry

CHEE 2404: Industrial Chemistry From: http://www.chem.tamu.edu/class/majors/chem470/Sulfuric_Acid-2008.PPT CHEE 2404: Industrial Chemistry

CHEE 2404: Industrial Chemistry Canadian Industry CHEE 2404: Industrial Chemistry

Consumer products from raw materials CHEE 2404: Industrial Chemistry

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 CHEE 2404: Industrial Chemistry

Overview of the petrochemical industry CHEE 2404: Industrial Chemistry

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’). CHEE 2404: Industrial Chemistry

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. CHEE 2404: Industrial Chemistry

World chemical market (1989) CHEE 2404: Industrial Chemistry

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. CHEE 2404: Industrial Chemistry

CHEE 2404: Industrial Chemistry 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. CHEE 2404: Industrial Chemistry

CHEE 2404: Industrial Chemistry USA Petroleum Industry USA has 163 operating refineries and 15.6 million barrels per day CHEE 2404: Industrial Chemistry

USA Chemicals Industry CHEE 2404: Industrial Chemistry

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! CHEE 2404: Industrial Chemistry

Total world energy consumption CHEE 2404: Industrial Chemistry

Fossil fuel reserves (reserves/production) for 1997 CHEE 2404: Industrial Chemistry

Petrochemical share of world oil CHEE 2404: Industrial Chemistry

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. CHEE 2404: Industrial Chemistry

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 CHEE 2404: Industrial Chemistry

Steam/power generation CHEE 2404: Industrial Chemistry

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). CHEE 2404: Industrial Chemistry

CHEE 2404: Industrial Chemistry 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. CHEE 2404: Industrial Chemistry

CHEE 2404: Industrial Chemistry Lower Alkenes from oil CHEE 2404: Industrial Chemistry

CHEE 2404: Industrial Chemistry Lower Alkenes from NG CHEE 2404: Industrial Chemistry

CHEE 2404: Industrial Chemistry Aromatics production CHEE 2404: Industrial Chemistry

Ammonia and methanol production CHEE 2404: Industrial Chemistry

Business-cash flowchart CHEE 2404: Industrial Chemistry

Petroleum Industry Technologies CHEE 2404: Industrial Chemistry

Chemicals Industry Technologies CHEE 2404: Industrial Chemistry

CHEE 2404: Industrial Chemistry Levels of development CHEE 2404: Industrial Chemistry

CHEE 2404: Industrial Chemistry Space and time scales CHEE 2404: Industrial Chemistry