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The BTX Chain: Benzene, Toluene, Xylene - Epurga, LLC ? ‚ 4 The BTX Chain: Benzene,...

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    4 The BTX Chain:Benzene,Toluene, Xylene

    4.1 Overview of the BTX Chain

    Benzene, Toluene, and Xylene Are Co-Products

    Benzene, toluene, and xylene are all aromaticcompounds1 important to the production ofpolymers, other chemicals, and numerousconsumer products (solvents, paints, polishes,pharmaceuticals) (see Figure 4-1). These threearomatics are often co-produced by catalyticreforming of naphtha, although other methods arealso employed in their manufacture. Toluene, forexample, can be hydroalkylated to form benzene.

    Benzene ranks fifteenth on the list of top fiftychemicals produced in the United States, withabout 15 billion pounds produced in 1997. Mostof the benzene produced is used in themanufacture of ethylbenzene, which is usedsolely to produce styrene and subsequently

    1 In the late nineteenth century aromatic referred tocompounds that had low hydrogen-to-carbon ratiosand were fragrant, as most were made from balsams,resins, or essential oils (e.g., bitter almond oil). Today,aromatics are characterized as compounds having fullyconjugated (hybridized unsaturated orbital) ringstructures, which may have 6 carbons, or 10 carbons,or many more carbons, and may also containheteroatoms. Ring structures with 6 carbons likecyclohexane are called naphthenes, and are notaromatics.

    Production of Benzene, Toluene, andXylene and Their Derivatives (1997)

    Benzene (14.9 billion lbs)Ethylbenzene (13.9 billion lbs)Styrene (11.4 billion lbs)Polystyrene (6.4 billion lbs)Cumene (5.8 billion lbs)Phenol (4.4 billion lbs)Acetone (2.9 billion lbs)Cyclohexane (2.2 billion lbs)Caprolactam (1.7 billion lbs)Nylon (1.2 billion lbs)Toluene (8.3 billion lbs)Toluene-diisocyanate (0.9 billion lbs)p-Xylene (7.9 billion lbs)o-Xylene (1.1 billion lbs)Terephthalic Acid (10 billion lbs)Phthalic Anhydride (1.0 billion lbs)Adipic Acid (2.0 billion lbs)

    Sources: CMA 1998, SPI 1998.

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    Figure 4-1. The BTX Chain (CMA 1998)

    polystyrene, an important polymer. Smallamounts of styrene are also used in themanufacture of ABS resins (acrylonitrile-butadiene-styrene). Ethylbenzene rankedsixteenth on the top fifty list in 1997, withnearly 14 billion pounds produced. Styrenefollowed closely, with about 11.4 billion poundsproduced. Polystyrene is the fourth largestthermoplastic produced, with over 6 billionpounds in 1997. Its primary uses include foodpackaging, appliances, and thermal insulation.

    About 22 percent of the benzene produced isused to manufacture cumene, which is usedsolely to produce phenol and acetone. Phenol isan intermediate in the production of phenolicresins, pharmaceuticals, and various plastics. Benzene, along with xylene and toluene, is alsoused as a component of gasoline. Its use for thispurpose is declining, however, as differentregions of the country impose limits on benzenebecause of its known carcinogenicity.

    Toluene ranked twenty-fifth on the list of the topfifty chemicals in 1997, with 8.3 billion poundsproduced. More than half of the tolueneproduced is used to manufacture benzene byhydroalkylation. Other important uses are theproduction of toluene-diisocyanate (TDI), amonomer for polyurethanes, and the manufactureof explosives (TNT).

    The most widely used isomers of xylene includeortho-xylene and para-xylene, named for therelative position of methyl (CH3) groups on thesix-carbon ring. Ortho indicates the groups aresubstituted on adjacent carbons; para indicatesthe groups are substituted on the first and fourthcarbons. Demand is much greater for p-xylene,which ranked twenty-sixth on the list of the topfifty chemicals in 1997 with about 7.9 billionpounds of production. It is used primarily tomanufacture terephathalic acid, an importantintermediate in the production of polyester fibersand resins (see Section 2 for more informationon polyester). Production of o-xylene was about

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    1 billion pounds in 1997, and this compound isused almost entirely to make phthalicanhydride, an intermediate in the synthesis ofplasticizers, pharmaceuticals, and otherchemicals (CMA 1998, CHEMX 1999, Orica1999.

    Demand for BTX and Their Derivatives IsClosely Linked to the Plastics Market

    Like most petrochemicals, the demand forbenzene, toluene, and xylenes is stronglylinked with consumer demand for plastics, theirprimary end-use. Currently, the demand forcertain plastics is relatively high demand (e.g.,polyethylene, polypropylene) but is weakeningfor others (e.g., polystyrene, polyvinyl chloride). Over-capacity, lower demand for exports fromAsia, and declining prices and margins willcontinue to be near-term problems for the BTXchemicals as well as for some of their end-products.

    The demand for cumene, which is producedfrom benzene, remains strong, however, and isbeing driven by steadily increasing consumptionof bisphenol A, an intermediate inpolycarbonate manufacture, and steady growthin the use of phenolic resins. Markets for bothof these derivatives are linked to a strongdemand in the downstream consumingindustries of transportation and construction.

    The strong underlying global demand forpolyester fibers, film, and bottle resins iskeeping the demand for p-xylene strong. Goodmargins have stimulated projects to constructadditional capacity for p-xylene production,which may lead to overcapacity in the future.

    The capacity for o-xylene production is in closeagreement with the demand for this product. Exports to South American markets have beenincreasing, and have helped to offset fallingshipments to the Asia Pacific region. In thefuture, some expansion is expected in the use ofo-xylene for herbicides, lubricant additives, andspecialty chemicals manufacture (CHEMX1999, CHEMWK 1999).

    4.1.1 BTX Manufacture

    The Same Process Can Be Used ToProduce Benzene, Toluene, and Xylenes

    Benzene was originally made solely from coaltar, until new processes began to emerge in the1950s. The new production methods were basedon the catalytic reforming of naphtha, and by1980 they had gradually eliminated the use ofcoal tar. Toluene and xylenes are also producedduring the production of benzene using the newerprocess. The amounts of each aromatic producedmay vary depending on current market demand,but typically, production of benzene is favored. Benzene produced from reformate accounts forabout 40 percent of petrochemical-basedbenzene. Another 40 percent is produced byextracting benzene from pyrolysis gas. About 20percent is produced by catalytichydrodealkylation of toluene or other methods.

    A typical flow diagram for production ofbenzene, toluene, and xylene from naphtha isshown in Figure 4-2. Naphtha feed enters areactor or series of reactors containing platinumcatalysts in a gas atmosphere (typically hydrogento suppress coke formation). Coke is usuallyremoved from the catalyst and the catalyst isregenerated and recycled to the reactor. Hydrogen is also recycled.

    The reformate is then subjected to furtherprocessing by various methods, depending on thedesired product slate: (1) solvent extraction ofmixed aromatics, (2) the separation of eacharomatic by distillation, or (3) the hydro-dealkylation of toluene.

    Solvent extraction processes use solvents such asdiethylene glycol, tetraethylene glycol, orsulfolane to extract the aromatic from non-aromatic compounds. These solvents also havehigh boiling points to make later fractionation ofindividual products easier. A typical productslate for deriving aromatics from naphthareformate (which is also subjected to solventextraction and fractionation) is shown in Table 4-1. Fractionation is used to separate and recoverthe solvent, which is then returned to the process.

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    Figure 4-2. Possible Configuration for Reforming of Naphtha To ProduceBenzene, Toluene, and Xylene (Chenier 1992, HP 1999, Orica 1999)

    Key Energy and Environmental Facts - Naphtha Reforming to Produce BTX

    Energy Emissions Effluents Wastes/Byproducts

    Net Energy use:

    Process Energy: 1,025 Btu/lbFeedstock: 299 Btu/lb (based onrefinery stock)

    Largest source - fugitiveemissions (benzene, toluene,xylenes, solvents)

    Largest source - processwater

    Raffinate, coke, spentcatalyst

    Table 4-1. Product Slate: BTX from Naphtha Reformate (% Yield)

    BenzeneTolueneXylenesTOTAL AROMATICS

    8.526.326.174.3

    When distillation is used, as shown in Figure 4-2, three columns are used to separate benzenefirst, then toluene, and then mixed xylenes. Thetoluene stream can be sold or rerouted to thetoluene trans-alkylation unit. The mixed xylene

    stream also contains ethylbenzene compounds,and can be routed to a number of process units,depending on the desired products. The bottomscolumn from the xylene column contains C9 orhigher aromatics and can be blended intodistillates or sold.

    Additional processes may be used to optimizeyields of benzene or p-xylene. These processesmay combine special units to produce ultra-high-purity p-xylene with toluene dealkylation units,which produce benzene from the toluene product

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    Figure 4-3. Toluene Hydrodealkylation to Produce Benzene (HP 1999, Orica 1999)

    Key Energy and Environmental Facts - Toluene Hydrodealkylation

    Energy Emissions Effluents Wastes/Byproducts

    Net Energy use:

    Process Energy: 1,117 Btu/lbFeedstock )Hc: 23,330 Btu/lb

    Largest source - fugitiveemissions (benzene, xylenes,toluene, solvents)

    Largest source - process water Nonaromatic byproducts

    stream. The mixed xylene and toluene cutsfrom naphtha reformate are the typicalfeedstocks to these units.

    There are a variety of technologies available forproduction of high-purity p-xylenes from mixedC8 isomer streams. Some are based onsimulated countercurrent adsorption, selectivecatalytic isomerizat

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