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THE CHEMICAL INDUSTRY

CHEE 2404: Industrial Chemistry. 2. OUTLINE. Structure of the Chemical IndustryRaw Materials and EnergyBase ChemicalsChemical Processes. CHEE 2404: Industrial Chemistry. 3. STRUCTURE OF THE CHEMICAL INDUSTRY. Raw materials are converted into products for other industries and consumers.Basic raw

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THE CHEMICAL INDUSTRY

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    1. THE CHEMICAL INDUSTRY

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

    3. 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.

    4. 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.

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

    6. 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.

    7. CHEE 2404: Industrial Chemistry 7

    8. CHEE 2404: Industrial Chemistry 8 Canadian Industry

    9. CHEE 2404: Industrial Chemistry 9 Consumer products from raw materials

    10. CHEE 2404: Industrial Chemistry 10 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

    11. CHEE 2404: Industrial Chemistry 11 Overview of the petrochemical industry

    12. CHEE 2404: Industrial Chemistry 12 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’).

    13. CHEE 2404: Industrial Chemistry 13 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.

    14. CHEE 2404: Industrial Chemistry 14 World chemical market (1989)

    15. CHEE 2404: Industrial Chemistry 15 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

    16. CHEE 2404: Industrial Chemistry 16 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.

    17. CHEE 2404: Industrial Chemistry 17 USA Petroleum Industry USA has 163 operating refineries and 15.6 million barrels per day

    18. CHEE 2404: Industrial Chemistry 18 USA Chemicals Industry

    19. CHEE 2404: Industrial Chemistry 19 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%

    20. CHEE 2404: Industrial Chemistry 20

    21. CHEE 2404: Industrial Chemistry 21 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

    22. CHEE 2404: Industrial Chemistry 22

    23. CHEE 2404: Industrial Chemistry 23

    24. CHEE 2404: Industrial Chemistry 24

    25. CHEE 2404: Industrial Chemistry 25

    26. CHEE 2404: Industrial Chemistry 26

    27. CHEE 2404: Industrial Chemistry 27

    28. CHEE 2404: Industrial Chemistry 28

    29. CHEE 2404: Industrial Chemistry 29 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!

    30. CHEE 2404: Industrial Chemistry 30 Total world energy consumption

    31. CHEE 2404: Industrial Chemistry 31 Fossil fuel reserves (reserves/production) for 1997

    32. CHEE 2404: Industrial Chemistry 32 Petrochemical share of world oil

    33. CHEE 2404: Industrial Chemistry 33 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.

    34. CHEE 2404: Industrial Chemistry 34 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

    35. CHEE 2404: Industrial Chemistry 35 Steam/power generation

    36. CHEE 2404: Industrial Chemistry 36 Steam saturation temp. vs pressure

    37. CHEE 2404: Industrial Chemistry 37 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).

    38. CHEE 2404: Industrial Chemistry 38 ICGCC

    39. CHEE 2404: Industrial Chemistry 39 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.

    40. CHEE 2404: Industrial Chemistry 40 Lower Alkenes from oil

    41. CHEE 2404: Industrial Chemistry 41 Lower Alkenes from NG

    42. CHEE 2404: Industrial Chemistry 42 Aromatics production

    43. CHEE 2404: Industrial Chemistry 43 Ammonia and methanol production

    44. CHEE 2404: Industrial Chemistry 44 Business-cash flowchart

    45. CHEE 2404: Industrial Chemistry 45 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.

    46. CHEE 2404: Industrial Chemistry 46 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)?

    47. CHEE 2404: Industrial Chemistry 47

    48. CHEE 2404: Industrial Chemistry 48 Chemicals Industry Technologies

    49. CHEE 2404: Industrial Chemistry 49 Levels of development

    50. CHEE 2404: Industrial Chemistry 50 Process development and levels of integration

    51. CHEE 2404: Industrial Chemistry 51 Space and time scales

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