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THE CHEMICAL INDUSTRY

THE CHEMICAL INDUSTRY. Revised from: http://chemicalengineering.dal.ca/Files/2_-_The_Chemical_Industry.ppt. OUTLINE. Structure of the Chemical Industry Raw Materials and Energy Base Chemicals Chemical Processes. STRUCTURE OF THE CHEMICAL INDUSTRY.

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THE CHEMICAL INDUSTRY

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

  2. 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. • About30,000 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. From: http://www.chem.tamu.edu/class/majors/chem470/Sulfuric_Acid-2008.PPT CHEE 2404: Industrial Chemistry

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

  10. 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. 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. USA Petroleum IndustryUSA 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 40 683 523 MP 10 493 453 LP 3 463 407 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. 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. Lower Alkenes from oil CHEE 2404: Industrial Chemistry

  31. Lower Alkenes from NG CHEE 2404: Industrial Chemistry

  32. 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. Levels of development CHEE 2404: Industrial Chemistry

  38. Space and time scales CHEE 2404: Industrial Chemistry

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