THE CHEMICAL INDUSTRY : THE CHEMICAL INDUSTRY
OUTLINE : OUTLINE Structure of the Chemical Industry
Raw Materials and Energy
Base Chemicals
Chemical Processes
STRUCTURE OF THE CHEMICAL INDUSTRY : 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.
Structure of the chemical industry : 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.
Structure of the chemical industry : Structure of the chemical industry
Where these chemicals go.. : 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.
Canadian Industry : Canadian Industry
Consumer products from raw materials : Consumer products from raw materials
Structure of the chemical industry : 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
Overview of the petrochemical industry : Overview of the petrochemical industry
Structure of the chemical industry : 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’).
Structure of the chemical industry : 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.
World chemical market (1989) : World chemical market (1989)
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. World chemical industry
Slide16 : 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.
USA Petroleum Industry USA has 163 operating refineries and 15.6 million barrels per day : USA Petroleum Industry USA has 163 operating refineries and 15.6 million barrels per day
USA Chemicals Industry : USA Chemicals Industry
Canadian Chemicals Industry : Canadian Chemicals Industry Canadian Chemical Producers Association
CCPA is the national trade association of Canadian chemical manufacturers, representing 70 companies
(http://www.ccpa.ca/index_e.html)
Canada: $45.9 billion in shipments for 2006 (Stats Can), up 3.6%
USA: $580 billion in shipments in 2006 up 5.3%
Slide20 : C&E News Jan 8, 2007
Slide21 : Canadian Chemical & Allied Industry Group
Canadian Association of Chemical Distributors (also have a formalized agreement)
Canadian Consumer Specialty Products Association (also have a formalized agreement)
Canadian Fertilizer Institute
Canadian Paints and Coatings Association
Canadian Plastics Industry Association
CropLife Canada
Rubber Association of Canada
Slide23 : Canadian Chemical Industry Locations Ontario 51%
Alberta 22%
Quebec 21%
BC 3%
Slide24 : www2.nrcan.gc.ca/es/es/energypicture/chap4_e.cfm
Slide25 : www2.nrcan.gc.ca/es/es/energypicture/chap4_e.cfm
Slide26 : www2.nrcan.gc.ca/es/es/energypicture/chap4_e.cfm
Slide27 : www2.nrcan.gc.ca/es/es/energypicture/chap4_e.cfm
RAW MATERIALS AND ENERGY : 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!
Total world energy consumption : Total world energy consumption
Fossil fuel reserves (reserves/production) for 1997 : Fossil fuel reserves (reserves/production) for 1997
Petrochemical share of world oil : Petrochemical share of world oil
Energy and the chemical industry : 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.
Energy and the chemical industry : 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
Steam/power generation : Steam/power generation
Steam saturation temp. vs pressure : Steam saturation temp. vs pressure
Energy and the chemical industry : 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).
ICGCC : ICGCC
BASE CHEMICALS : 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.
Lower Alkenes from oil : Lower Alkenes from oil
Lower Alkenes from NG : Lower Alkenes from NG
Aromatics production : Aromatics production
Ammonia and methanol production : Ammonia and methanol production
Business-cash flowchart : Business-cash flowchart
CHEMICAL PROCESSES : CHEMICAL PROCESSES Various disciplines are integrated in chemical process technology.
They can be divided according to their scale:
scale independent
Microlevel
Mesolevel
Macrolevel
Villermaux shows the discipline of ChE in an enlightening way.
Chemical processes: what we need to know : Chemical processes: what we need to know Which reactions are involved?
What are the the phases, thermodynamics, kinetics and operating conditions (T & P)?
Is a catalyst used and if so is regeneration needed?
Is gas or liquid recycle needed?
Do we need to purify the feed?
How are the products separated?
What are the HSE & sustainability issues?
Can different operations be integrated in one piece of equipment (process intensification)?
What are the economics (comparison between processes)?
Slide47 : Petroleum Industry Technologies
Chemicals Industry Technologies : Chemicals Industry Technologies
Levels of development : Levels of development
Process development and levels of integration : Process development and levels of integration
Space and time scales : Space and time scales