List of Petrochemicals (for Non-chemical engineer)

Bhavik Kasundra · December 26, 2024

energy   industry   analysis

Petrochemicals and raw materials, Process, final products & it’s applications (Using AI).

  • Ethylene
  • Propylene
  • Benzene
  • Toluene
  • Xylenes
  • Butadiene
  • Methanol
  • Phthalic Anhydride
  • Ethylene Oxide
  • Acrylonitrile
  • Vinyl Chloride Monomer (VCM)
  • Styrene
  • Caprolactam
  • Terephthalic Acid (PTA)
  • Bisphenol A (BPA)
  • Cumene
  • Acetic Acid
  • Formaldehyde
  • Ethylene Dichloride (EDC)
  • Isopropyl Alcohol (IPA)

1. Ethylene (C2H4)

  • Raw Materials: Ethane (from natural gas), Naphtha (from crude oil)
  • Process: Steam cracking (high-temperature pyrolysis)
  • Final Products:
    • Polyethylene (PE): Plastics for packaging, films, containers
    • Ethylene oxide: Used to produce ethylene glycol (antifreeze, polyester fibers)
    • Ethylene dichloride: Precursor to polyvinyl chloride (PVC) pipes, construction materials
  • Applications: Packaging, automotive, construction, textiles
  • Financial Estimates:
    • Market Value: Polyethylene market was valued at over USD 100 billion in recent years and is expected to grow.
    • Production Cost: Highly variable based on feedstock prices (ethane vs. naphtha). US producers with access to cheap ethane have a cost advantage.

2. Propylene (C3H6)

  • Raw Materials: Propane (from natural gas), as a co-product of ethylene production in steam crackers
  • Process: Steam cracking, Fluid Catalytic Cracking (FCC) in refineries
  • Final Products:
    • Polypropylene (PP): Plastics for automotive parts, packaging, fibers
    • Acrylonitrile: Used to produce acrylic fibers and ABS plastics
    • Propylene oxide: Used to produce polyurethane foams
  • Applications: Automotive, packaging, construction, textiles, furniture
  • Financial Estimates:
    • Market Value: Polypropylene market is substantial, comparable in scale to polyethylene.
    • Production Cost: Similar to ethylene, depends on feedstock and cracking efficiency.

3. Benzene (C6H6)

  • Raw Materials: Naphtha (from crude oil)
  • Process: Catalytic reforming of naphtha, Toluene hydrodealkylation
  • Final Products:
    • Ethylbenzene: Precursor to styrene, used to produce polystyrene plastics
    • Cumene: Precursor to phenol and acetone
    • Cyclohexane: Used to produce nylon
  • Applications: Plastics, resins, synthetic fibers, detergents
  • Financial Estimates:
    • Market Value: Benzene market is significant due to its wide range of derivatives.
    • Production Cost: Influenced by crude oil prices and refinery operations.

4. Toluene (C7H8)

  • Raw Materials: Naphtha (from crude oil)
  • Process: Catalytic reforming of naphtha
  • Final Products:
    • Benzene (via hydrodealkylation)
    • Xylenes
    • Toluene diisocyanate (TDI): Used to produce polyurethane foams
  • Applications: Solvents, gasoline additives, polyurethane production
  • Financial Estimates:
    • Market Value: Toluene market is tied to benzene and xylene demand.
    • Production Cost: Dependent on crude oil and refining processes.

5. Xylenes (C8H10)

  • Raw Materials: Naphtha (from crude oil)
  • Process: Catalytic reforming of naphtha
  • Final Products:
    • p-Xylene: Oxidized to produce terephthalic acid (PTA), a key component of PET plastics
    • o-Xylene: Oxidized to produce phthalic anhydride, used in plasticizers and resins
  • Applications: PET bottles, polyester fibers, plasticizers
  • Financial Estimates:
    • Market Value: PET market is large, driving p-xylene demand.
    • Production Cost: Related to crude oil and refining, with additional costs for xylene separation.

6. Butadiene (C4H6)

  • Raw Materials: Byproduct of ethylene production in steam crackers, butane dehydrogenation
  • Process: Extraction from C4 streams in steam cracking units, catalytic dehydrogenation of butane
  • Final Products:
    • Styrene-butadiene rubber (SBR): Used in tires, footwear
    • Polybutadiene rubber (BR): Used in tires, high-impact plastics
    • Acrylonitrile-butadiene-styrene (ABS): Used in automotive parts, appliances
  • Applications: Tires, automotive components, plastics, footwear
  • Financial Estimates:
    • Market Value: Butadiene market is closely linked to the automotive and tire industries.
    • Production Cost: Influenced by crude oil and natural gas prices, as well as steam cracking economics.

7. Methanol (CH3OH)

  • Raw Materials: Natural gas (methane)
  • Process: Steam reforming of natural gas followed by catalytic synthesis
  • Final Products:
    • Formaldehyde: Used to produce resins, adhesives, and plastics
    • Methyl tert-butyl ether (MTBE): Used as a gasoline additive
    • Acetic acid: Used to produce various chemicals and polymers
  • Applications: Building materials, automotive, plastics, fuels
  • Financial Estimates:
    • Market Value: Methanol market is significant due to its diverse applications.
    • Production Cost: Primarily driven by natural gas prices.

8. Phthalic Anhydride (C8H4O3)

  • Raw Materials: o-Xylene
  • Process: Catalytic oxidation of o-xylene
  • Final Products:
    • Plasticizers: Used to make plastics more flexible
    • Resins: Used in coatings, paints, and fiberglass-reinforced plastics
  • Applications: Construction, automotive, packaging, consumer goods
  • Financial Estimates:
    • Market Value: Phthalic anhydride market is tied to the demand for plasticizers and resins.
    • Production Cost: Dependent on o-xylene prices and oxidation process efficiency.

9. Ethylene Oxide (C2H4O)

  • Raw Materials: Ethylene
  • Process: Catalytic oxidation of ethylene
  • Final Products:
    • Ethylene glycol: Used in antifreeze, polyester fibers, and PET plastics
    • Ethoxylates: Used in detergents, surfactants, and personal care products
  • Applications: Automotive, textiles, packaging, household products
  • Financial Estimates:
    • Market Value: Ethylene oxide market is substantial due to the widespread use of its derivatives.
    • Production Cost: Influenced by ethylene prices and oxidation process efficiency.

10. Acrylonitrile (C3H3N)

  • Raw Materials: Propylene, ammonia
  • Process: Catalytic ammoxidation of propylene
  • Final Products:
    • Acrylic fibers: Used in textiles, carpets
    • Acrylonitrile-butadiene-styrene (ABS): Used in automotive parts, appliances
    • Nitrile rubber: Used in seals, gaskets, and gloves
  • Applications: Textiles, automotive, household goods, industrial products
  • Financial Estimates:
    • Market Value: Acrylonitrile market is linked to the demand for fibers, plastics, and elastomers.
    • Production Cost: Dependent on propylene and ammonia prices, as well as catalyst performance.

11. Vinyl Chloride Monomer (VCM) (C2H3Cl)

  • Raw Materials: Ethylene, chlorine
  • Process: Direct chlorination of ethylene or oxychlorination of ethylene
  • Final Products:
    • Polyvinyl chloride (PVC): Used in pipes, construction materials, flooring
  • Applications: Construction, infrastructure, packaging
  • Financial Estimates:
    • Market Value: PVC market is large and driven by construction activity.
    • Production Cost: Influenced by ethylene and chlorine prices, as well as production technology.

12. Styrene (C8H8)

  • Raw Materials: Ethylbenzene (produced from benzene and ethylene)
  • Process: Dehydrogenation of ethylbenzene
  • Final Products:
    • Polystyrene (PS): Used in packaging, insulation, disposable tableware
    • Styrene-butadiene rubber (SBR): Used in tires
    • Acrylonitrile-butadiene-styrene (ABS): Used in automotive parts, appliances
  • Applications: Packaging, automotive, construction, consumer goods
  • Financial Estimates:
    • Market Value: Styrene market is linked to the demand for its various polymer derivatives.
    • Production Cost: Dependent on benzene and ethylene prices, as well as dehydrogenation efficiency.

13. Caprolactam (C6H11NO)

  • Raw Materials: Cyclohexane (derived from benzene)
  • Process: Several routes, including cyclohexanone oxime rearrangement
  • Final Products:
    • Nylon 6: Used in fibers, textiles, carpets, and plastics
  • Applications: Textiles, automotive, industrial products
  • Financial Estimates:
    • Market Value: Caprolactam market is tied to the demand for nylon 6 fibers and resins.
    • Production Cost: Influenced by benzene prices and the specific production process used.

14. Terephthalic Acid (PTA) (C8H6O4)

  • Raw Materials: p-Xylene
  • Process: Oxidation of p-xylene
  • Final Products:
    • Polyethylene terephthalate (PET): Used in bottles, packaging, and polyester fibers
  • Applications: Packaging, textiles, beverage containers
  • Financial Estimates:
    • Market Value: PTA market is substantial due to the widespread use of PET.
    • Production Cost: Dependent on p-xylene prices and oxidation process efficiency.

15. Bisphenol A (BPA) (C15H16O2)

  • Raw Materials: Phenol, acetone
  • Process: Condensation of phenol and acetone
  • Final Products:
    • Polycarbonate (PC): Used in electronics, automotive parts, and safety equipment
    • Epoxy resins: Used in coatings, adhesives, and composites
  • Applications: Electronics, automotive, construction, packaging
  • Financial Estimates:
    • Market Value: BPA market is significant due to its use in polycarbonate and epoxy resins.
    • Production Cost: Influenced by phenol and acetone prices, as well as production technology.

16. Cumene (C9H12)

  • Raw Materials: Benzene, propylene
  • Process: Alkylation of benzene with propylene
  • Final Products:
    • Phenol: Used to produce bisphenol A (BPA), phenolic resins
    • Acetone: Used as a solvent and in the production of various chemicals
  • Applications: Plastics, resins, solvents
  • Financial Estimates:
    • Market Value: Cumene market is driven by the demand for phenol and acetone.
    • Production Cost: Dependent on benzene and propylene prices, as well as alkylation efficiency.

17. Acetic Acid (CH3COOH)

  • Raw Materials: Methanol, carbon monoxide
  • Process: Carbonylation of methanol (Monsanto process, Cativa process)
  • Final Products:
    • Vinyl acetate monomer (VAM): Used to produce polyvinyl acetate (PVA) adhesives and polymers
    • Acetic anhydride: Used in the production of cellulose acetate and other chemicals
  • Applications: Adhesives, polymers, solvents, food preservation
  • Financial Estimates:
    • Market Value: Acetic acid market is significant due to its wide range of applications.
    • Production Cost: Primarily influenced by methanol and carbon monoxide prices.

18. Formaldehyde (CH2O)

  • Raw Materials: Methanol
  • Process: Oxidation of methanol
  • Final Products:
    • Urea-formaldehyde resins: Used in wood adhesives, particleboard
    • Phenol-formaldehyde resins: Used in plywood, molding compounds
    • Melamine-formaldehyde resins: Used in laminates, tableware
  • Applications: Building materials, furniture, adhesives
  • Financial Estimates:
    • Market Value: Formaldehyde market is tied to the construction and furniture industries.
    • Production Cost: Dependent on methanol prices and oxidation process efficiency.

19. Ethylene Dichloride (EDC) (C2H4Cl2)

  • Raw Materials: Ethylene, chlorine
  • Process: Direct chlorination of ethylene
  • Final Products:
    • Vinyl chloride monomer (VCM): Precursor to polyvinyl chloride (PVC)
  • Applications: Production of PVC
  • Financial Estimates:
    • Market Value: EDC market is directly linked to the PVC market.
    • Production Cost: Influenced by ethylene and chlorine prices.

20. Isopropyl Alcohol (IPA) (C3H8O)

  • Raw Materials: Propylene
  • Process: Hydration of propylene
  • Final Products:
    • Solvents: Used in cleaning products, pharmaceuticals, and cosmetics
    • Disinfectants: Used in hand sanitizers and medical applications
  • Applications: Cleaning products, pharmaceuticals, cosmetics, disinfectants
  • Financial Estimates:
    • Market Value: IPA market has seen increased demand due to its use in hand sanitizers.
    • Production Cost: Dependent on propylene prices and hydration process efficiency.

21. Aniline (C6H5NH2)

  • Raw Materials: Benzene, nitric acid
  • Process: Nitration of benzene to nitrobenzene, followed by reduction to aniline
  • Final Products:
    • Methylene diphenyl diisocyanate (MDI): Used to produce polyurethane foams
    • Dyes and pigments: Used in textiles, paints, and inks
  • Applications: Polyurethane production, textile dyeing, rubber processing
  • Financial Estimates:
    • Market Value: Aniline market is linked to the demand for polyurethanes and dyes.
    • Production Cost: Dependent on benzene and nitric acid prices, as well as production technology.

22. Ethylene Glycol (C2H6O2)

  • Raw Materials: Ethylene oxide
  • Process: Hydration of ethylene oxide
  • Final Products:
    • Polyester fibers: Used in textiles and clothing
    • Polyethylene terephthalate (PET): Used in bottles and packaging
    • Antifreeze: Used in automotive cooling systems
  • Applications: Textiles, packaging, automotive
  • Financial Estimates:
    • Market Value: Ethylene glycol market is substantial due to its diverse applications.
    • Production Cost: Influenced by ethylene oxide prices.

23. Phenol (C6H5OH)

  • Raw Materials: Cumene
  • Process: Cumene hydroperoxide process
  • Final Products:
    • Bisphenol A (BPA): Used to produce polycarbonate plastics and epoxy resins
    • Phenolic resins: Used in plywood, laminates, and molding compounds
  • Applications: Plastics, resins, adhesives
  • Financial Estimates:
    • Market Value: Phenol market is tied to the demand for BPA and phenolic resins.
    • Production Cost: Dependent on cumene prices and process efficiency.

24. Vinyl Acetate Monomer (VAM) (C4H6O2)

  • Raw Materials: Acetic acid, ethylene
  • Process: Reaction of acetic acid with ethylene in the presence of a catalyst
  • Final Products:
    • Polyvinyl acetate (PVA): Used in adhesives, paints, and coatings
    • Polyvinyl alcohol (PVOH): Used in paper coatings, textiles, and adhesives
  • Applications: Adhesives, paints, coatings, textiles
  • Financial Estimates:
    • Market Value: VAM market is driven by the demand for PVA and PVOH.
    • Production Cost: Influenced by acetic acid and ethylene prices.

25. Methyl Methacrylate (MMA) (C5H8O2)

  • Raw Materials: Acetone, methanol, sulfuric acid
  • Process: Several routes, including the acetone cyanohydrin (ACH) process
  • Final Products:
    • Polymethyl methacrylate (PMMA): Used in acrylic glass, signs, and displays
  • Applications: Signage, displays, automotive, construction
  • Financial Estimates:
    • Market Value: MMA market is linked to the demand for acrylic plastics.
    • Production Cost: Dependent on raw material prices and production process.

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