ContentsContents
Chemical industry & Catalysis
Origin of Petrochemicals
Basic / Building block chemicals
Basic chemicals to Petrochemicals
Petrochemical processes & catalysts
Ethylene, Propylene & Butadiene by thermal cracking
Alternative routes for Basic chemicals
Chemical Industry-The Fact Sheet
70000 products
10 Million direct employees
50 Million indirect employees
Wide range of products/processes
/ feed-stocks
Enabling better quality of life
Annual growth rate 2.4 %
Global enterprise valued at $2.2 Trillion …… and growing
Chemical Industry- Products pattern
Chemicals- Intricately woven with our day to day life
Petrochemicals-37%Petrochemicals-37%
Energy
Chemicals & Fertilizers
Petrochemicals
Transport
Petroleum Refining
95%
Petroleum Refining- The Mother IndustryPetroleum Refining- The Mother Industry
5-6%
CR
UD
E OI
L
Product SlatesProduct Slates
Petroleum Petroleum FuelsFeed-stocksHydrogenLubricantsSyngasSulfur
Petrochemical feed-Petrochemical feed-stocksstocks
CC22-C-C33 gas gas
LPGLPG
CC44 stream stream
Naphtha for light Naphtha for light olefinsolefins
Naphtha for Naphtha for aromaticsaromatics
KeroseneKerosene
Gas oil for crackingGas oil for cracking
CRUDE OIL
REFINARY
FEEDSTOCKSGas, Naphtha, Gas Oil, Kerosene
PETROCHEMICAL INDUSTRY
BASIC CHEMICALSEthylene, Propylene, 1.3-Butadiene &
BTX,
PETROCHEMICALSPE,PP,PVC,PS,PBR,MEG,LAB,ACN, AF, PTA, PHA, MA,CPL
Petrochemicals- The OriginPetrochemicals- The Origin
Basic/Building block Chemicals
Ethylene
Propylene
Butadiene (1,3)
Benzene
Toulene
Xylenes
Petrochemicals from EthylenePetrochemicals from Ethylene
Petrochemicals from PropylenePetrochemicals from Propylene
AdiponitrileADN
PolybutadieneRubber
PBR
Styrene-ButadieneRubber SBR
Acrylonitrile-Butadiene
-Styrene ABS
Butadiene
Petrochemicals from ButadienePetrochemicals from ButadienePetrochemicals from BPetrochemicals from B
Specialty Polymers /Chemicals
Petrochemicals from BenzenePetrochemicals from Benzene
Toluene
Specialty/Functionalized
chemicals
XylenesBenzene
Petrochemicals from ToluenePetrochemicals from Toluene
Xylenes
O-Xylenep-Xylenem-Xylene
Phthalic anhydrideTerephthalic acidPTA
Iso-phthalic acid
PlasticizersPolyestersPET
Petrochemicals from XylenesPetrochemicals from Xylenes
Table.3. Major petrochemical processes & Table.3. Major petrochemical processes & catalystscatalysts
Process Catalysts/Processes
Aromatics
Naphtha reforming- Production of Gasoline & BTX
Pt-Re/Al2O3, Pt-Sn/Al2O3,Semi-regenerative/ CCRUOP/Axens/Criterion/Chevron/IPCL/RIL
Xylene Isomerization- Towards maximization of p-Xylene- EB Conversion/ EB dealkylation prcesses
ZSM-5 CompositeUOP, Axens, Exxon-MobilZeolyst , IPCL/RIL
C7+C9 Aromatics Transalkylation- Upgradation of low value C7& C9 streams, towards maximization of p-Xylene
ZSM-5 CompositeUOP, Axens, Exxon-Mobil,SK Corpn
Toluene Disproportionation- Up gradation of low value C7 stream- Value added products- Benzene & p- Xylene
ZSM-5 CompositeUOP, Axens, Exxon-Mobil,
Alkylation of Toluene/ Ethylbenzne- Value added products- p-Xylene & PDEB
Pore regulated ZSM-5 IPCL/RIL, UOP
Dehydrogenation
C3 ,C4 paraffins to Olefins- Monomers- Propylene, Iso-butene
Cr2 O3/Al2O3, Pt-Sn/Al2O3, UOP, CATOFIN, Phillips, Linde
C10-C13 paraffins to Mono olefins- For alkylation with Benzene to Linear Alkyl Benzene (LAB)
Pt-Sn/Al2O3,UOP, IFP,IPCL/RIL
Ethyl benzene to StyreneFe-K/Al2O3
UOP
Hydrogenation
Acetylenics in C2/C3/C4 hydrocarbon streams- Purification of monomers
Pd/Ni supported on alumina with promotersAxens, Sud-Chemie, BASF
Benzene to Cyclohexane- For caprolactum production
Ni/Alumina, Pt/AluminaAxens, SC,UOP
Hydrogenation of Oils/Fats Ni/Alumina
Purification of PTA- removal of 4-CBA
Pd/CarbonBASF, Sud-Chemie,Chemit
Hydrogenation of unsaturated organic compounds
Supported Ni/Pd with promoters
Oxidation /Epoxidation /Oxychlrination / Oxidation /Epoxidation /Oxychlrination / AmmoxidationAmmoxidation
Ethylene to Ethylene oxidePromoted Ag/Alumina, DOW,Shell,Sci.Design
Ethylene to Acetic acid Supported Pd
Ethylene+ HCl to Ethylene dichloride CuCl2- KCl/Alumina
BASF, KNF, Oxyvinyl
Propylene to Acrylonitrile Molybdates of Bi,Fe,Ni/Silica Ineos
Propylene to Acrylic acid V-P-O,Ineos
Propylene to Propylene oxide Supported Mo Oxides/Au
O-Xylene to Phthalic anhydride Vanadia/TiO2
P-Xylene to Purified Terephthalic acid(PTA)
Co-Mn fatty acids
Butane to Maleic anhydride V-P-O, Ineos
Syngas conversionsSyngas conversions
CO+2H2→ CH3OH ZnO-CuO-Chromia
CO+H2→ n-Paraffins (Fischer-Tropsch)
Supported Co/Fe with promoters
CO + CH3OH→ Acetic acid Rh-,Ir-Iodide promoted
Polymer Processes
Ethylene to PolyethyleneLDPE, LLDPE, HDPE
High pressure tubular process (LDPE)Chevron-Phillips slurry processBasell Spherilene process ( LLDPE/HDPE)NOVA- Sclairtech process ( LLDPE/HDPE)
Propylene to PolypropylenePP, PE Copolymers
Basell Spheripol PP processDow UNIPOL PP processBorstar PP process
Vinyl chloride to Polyvinyl chloride PVC
Innovyl Suspension PVCUHDE, Goodrich process
Polymer Processes
Ethylene to PolyethyleneLDPE, LLDPE, HDPE
High pressure tubular process (LDPE)Chevron-Phillips slurry processBasell Spherilene process ( LLDPE/HDPE)NOVA- Sclairtech process ( LLDPE/HDPE)
Propylene to PolypropylenePP, PE Copolymers
Basell Spheripol PP processDow UNIPOL PP processBorstar PP process
Vinyl chloride to Polyvinyl chloride PVC
Innovyl Suspension PVCUHDE, Goodrich process
(SRT-Heaters)
S as DMDS is injected to control CO & Coke
Selective hydrogenation of C2,C3 & C4 acetylenes in olefinic streams are the critical processes to get pure C2,C3 & C4 olefins
Propylene: Supply-Demand gap
C2H4 + C4H8 2 C3H6 Can be a stand alone unit or integrated with cracker/FCC unit
Low investment, less energy intensive, attractive returns
High propylene/ethylene yield ratios, varying from 0.5 to 1.1
Use of low cost C4 stream
Process technologies
META-4 ® (Axens – IFP Group Technologies)
OCT ® Olefins Conversion Technology (ABB Lummus)
UOP’s process
Olefin metathesis
Depends on relative costs of ethylene & propyleneDepends on relative costs of ethylene & propylene
Metathesis- Catalysts & Process Metathesis- Catalysts & Process conditionsconditions
Alternative routes to PropyleneAlternative routes to Propylene
Olefin Inter conversion Processes
• Catalytic cracking of C4- C5 streams or the light naphtha streams in a fixed or fluidized bed reactor
• Compatible with crackers and FCC units• Unlike metathesis, do not consume ethylene.
Process technologies
• Olefin Cracking Process (UOP-ATOFINA)• Propylur (Lurgi)• PCC process (Exxon –Mobil)• SUPERFLEX ® (Lyondell/Kellogg)• Mobil’s Olefin Inter conversion Process (MOI)
