1. THE CHEMICAL INDUSTRY Revised from:

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

3. 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

4. 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

5. Structure of the chemical industry
CHEE 2404: Industrial Chemistry

6. 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

7. CHEE 2404: Industrial Chemistry

8. CHEE 2404: Industrial Chemistry
From:
CHEE 2404: Industrial Chemistry

9. CHEE 2404: Industrial Chemistry
From:
CHEE 2404: Industrial Chemistry

10. CHEE 2404: Industrial Chemistry
Canadian Industry
CHEE 2404: Industrial Chemistry

11. Consumer products from raw materials
CHEE 2404: Industrial Chemistry

12. 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

13. Overview of the petrochemical industry
CHEE 2404: Industrial Chemistry

14. 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

15. 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

16. World chemical market (1989)
CHEE 2404: Industrial Chemistry

17. 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

18. 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

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

20. USA Chemicals Industry
CHEE 2404: Industrial Chemistry

21. 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

22. Total world energy consumption
CHEE 2404: Industrial Chemistry

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

24. Petrochemical share of world oil
CHEE 2404: Industrial Chemistry

25. 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

26. 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 MP LP
CHEE 2404: Industrial Chemistry

27. Steam/power generation
CHEE 2404: Industrial Chemistry

28. 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

29. 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

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

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

32. CHEE 2404: Industrial Chemistry
Aromatics production
CHEE 2404: Industrial Chemistry

33. Ammonia and methanol production
CHEE 2404: Industrial Chemistry

34. Business-cash flowchart
CHEE 2404: Industrial Chemistry

35. Petroleum Industry Technologies
CHEE 2404: Industrial Chemistry

36. Chemicals Industry Technologies
CHEE 2404: Industrial Chemistry

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

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