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Benzene/Toluene 93-7

May 1997

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TABLE OF CONTENTS

Page

I SUMMARY 1

A. COMMERCIAL TECHNOLOGY 1

1. General 1

2. Technology 1

(a) Production from Catalytic Reformate 1

(b) Production from Pyrolysis Gasoline 2

(c) Production from Coke Oven Light Oil 3

(d) Toluene Conversion 3

3. Economics 4B. DEVELOPING TECHNOLOGY 4

1. General 4

2. Economics 7

C. COMMERCIAL ANALYSIS 9

1. Benzene 9

2. Toluene 11

I I COMMERCIAL TECHNOLOGY 12

A. INTRODUCTION 12B. FEEDSTOCK PRODUCTION 12

1. Refinery Sources of Benzene 12

(a) General 12

(b) The Effect of Reformulated Gasoline on Aromatics

Production in the United States 13

2. Other Sources 16

(a) Pyrolysis Gasoline 16

(b) Production from Coke Oven Light Oil 19

(c) Toluene Conversion 19C. OVERVIEW OF BENZENE/TOLUENE RECOVERY 20

1. Aromatics Extraction 20

2. BTX Separation 22

3. Dealkylation Processes 22

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D. ECONOMICS 22

1. Basis 22

(a) Feedstock Evaluation 22

(b) Investment Basis 24

(c) Production Cost Basis 24

2. BTX 25

(a) Reformate 25

(b) Pyrolysis Gasoline 283. Benzene Production From Coke Oven Light Oil 36

4. Benzene From Toluene 36

I II DEVELOPING TECHNOLOGY 43

A. INTRODUCTION 43

B. AROMATICS FROM C2 TO C4 PARAFFINS AND OLEFINS 44

1. Alpha Process (Sanyo/Asahi) 44

2. CYCLAR Process (BP/UOP) 46

3. Z-Forming Process (Mitsubishi/Chiyoda) 51

4. Aroformer Process (IFP/Salutec) 53

5. Mobil's Process 56

6. Pyroform Process (KTI) 59

C. LIGHT NAPHTHA REFORMING (AROMAX) 62

D. ECONOMICS 68


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TABLE OF CONTENTS

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IV MARKET ANALYSIS 79

A. BENZENE 79

1. Applications 79

(a) Introduction 79

(b) Ethylbenzene/Styrene 79

(c) Cumene/Phenol (and Acetone) 81

(d) Cyclohexane 82

(e) Nitrobenzene 82(f) Chlorobenzene 83

(g) Alkylbenzene 84

(h) Maleic Anhydride 85

(i) Other 85

2. United States 86

(a) Demand 86

(b) Supply 88

(1) Aromatics from Catalytic Reforming 88

(2) Aromatics from Olefin Plants 89

(3) Aromatics from Coal Tar Processing 89

(4) Benzene from Toluene Hydrodealkylation

and Disproportionation 90

(5) Trade 90

(6) Capacity 91

(c) Supply/Demand Balance 91

3. Europe 93

(a) Demand 93

(b) Supply 98

(c) Benzene Trade 102

(c) Supply/Demand Balance 104

4. East Asian Summary 105


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B. TOLUENE 107

1. Applications 107

(a) Introduction 107

(b) Solvents 108

(c) Toluene Diisocyanate 108

(d) Phenol 108

(e) Caprolactam 109

(f) Other 1092. United States 110

(a) Demand 110

(b) Supply 111

3. Europe 113

(a) Demand 113

(b) Supply and Supply/Demand Balance 115

REFERENCES 120


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TABLES

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Table I.A.1 Typical BTX Compositions from Pygas and Reformate 2

Table I.A.2 Cost of Production Summary 5

Table I.C.1 U.S. Benzene Supply/Demand Balance, 1990-2000 9

Table I.C.2 West European Benzene Supply/Demand Balance, 1994-2000 10

Table I.C.3 East Asian Benzene Supply/Demand Balance, 1991-2000 11

Table II.B.1 Reformer Yields at Different Severities 15

Table II.B.2 Pyrolysis Gasoline and Aromatics Yields in Steam Crackers 16

Table II.B.3 Effect of Cracking Severity on Pyrolysis Gasoline andAromatics Yields 17

Table II.B.4 Pyrolysis Gasoline Analysis, Composition and Properties 18

Table II.D.1 U.S. Gulf Coast Feedstock, By-product, and Utility Prices,

First Quarter 1994 23

Table II.D.2 Production Cost Estimate of BTX via Reformate Extraction

(13%B, 40%T, 47%X) 26

Table II.D.3 Production Cost Estimate of BTX via Reformate Extraction

(17%B, 39%T, 44%X) 27

Table II.D.4 Production Cost Estimate of Benzene via Reformate Extraction

(>10 wt% BZ) 29

Table II.D.5 Production Cost Estimate of Benzene via Reformate Extraction

(<7 wt% BZ) 30

Table II.D.6 Production Cost Estimate of Benzene via Solvent Extraction

of Pygas 33

Table II.D.7 Production Cost Estimate of Benzene via Extractive Distillation

of Pygas 34

Table II.D.8 Production Cost Estimate of Benzene via Bulk Dealkylation

of Pygas 35

Table II.D.9 Summary of Benzene Production Costs from Pygas 32

Table II.D.10 Production Cost Estimate of Benzene via Litol from Coke Oven

Light Oil 37


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Table II.D.11 Production Cost Estimate of Benzene via Toluene

Hydrodealkylation 38

Table II.D.12 Production Cost Estimate of Benzene via Toluene

Disproportionation 39

Table II.D.13 Production Cost Estimate of Benzene via Detol Process 42

Table III.B.1 Alpha Process Yield Data 45

Table III.B.2 Material Balance for the CYCLAR Process 50

Table III.B.3 Z-Forming Process Yields 53Table III.B.4 Aroformer Process Yield Data 54

Table III.B.5 Yield Pattern for Ethane Processing Using Mobil Technology 56

Table III.B.6 Aromatics Yield - Thermal Pyroform Process 62

Table III.C.1 Once-Through Aromax Yields from Paraffinic Naphtha 63

Table III.C.2 Aromax Reforming Design Parameters 67

Table III.D.1 Raw Material Prices 68

Table III.D.2 Production Cost Estimate of BTX via Mobil Process 70

Table III.D.3 Production Cost Estimate of BTX via Pyroform Process 71

Table III.D.4 Production Cost Estimate of BTX via CYCLAR and Separation 72Table III.D.5 Production Cost Estimate of BTX via Z-Forming and Separation 74

Table III.D.6 Production Cost Estimate of BTX via Aromax 75

Table IV.A.1 U.S. Petrochemical Benzene Demand, 1992-2000 87

Table IV.A.2 U.S. Benzene Supply, 1990-2000 88

Table IV.A.3 U.S. Benzene Capacity, 1993 92

Table IV.A.4 U.S. Benzene Supply/Demand Balance, 1990-2000 91

Table IV.A.5 West European Benzene Consumption by End Use, 1990-1994 93

Table IV.A.6 West European Benzene Consumption by Country, 1990-1994 94

Table IV.A.7 West European Benzene Demand, 1991-2000 97

Table IV.A.8 West European Benzene Capacity, 1994 99-101

Table IV.A.9 West European Benzene Trade, 1990-2000 103

Table IV.A.10 West European Benzene Supply/Demand Balance, 1990-1994 104

Table IV.A.11 West European Benzene Supply/Demand Balance, 1994-2000 104

Table IV.A.12 East Asian Benzene Demand, 1991-2000 105

Table IV.A.13 East Asian Benzene Capacity, 1991-2000 106


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Table IV.A.14 East Asian Benzene Supply, 1991-2000 106

Table IV.A.15 East Asian Benzene Supply/Demand Balance, 1991-2000 107

Table IV.B.1 U.S. Toluene Demand for Chemical Uses, 1992-2000 110

Table IV.B.2 U.S. Toluene Capacity by Producer, 1993-1994 112

Table IV.B.3 West European Toluene Demand, 1991-2000 114

Table IV.B.4 West European Toluene Extraction Capacity, 1994 116-117

Table IV.B.5 West European Toluene Supply and Demand, 1991-2000 119


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FIGURES

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Figure I.B.1 Production Cost Comparison of Developing BTX

Technology, 1st Qtr 1994 8

Figure II.D.1 Benzene via Solvent Extraction from Reformate: Sensitivity

to Toluene Value 31

Figure II.D.2 Sensitivity to Feedstock Value: Benzene from Toluene 40

Figure III.B.1 UOP/BP Cyclar Process for LPG Aromatization 48

Figure III.B.2 Z-Forming Process Flow Diagram 52

Figure III.B.3 Aromizing/Aroformer Process Overall Flowplan 55

Figure III.B.4 Aromatics from Ethane: Mobil Process 57

Figure III.B.5 Pyroform Process Flow Diagram 60

Figure III.C.1 BTX from NGL Overall Flow Diagram 65

Figure III.C.2 Chevron's Aromax Process: Paraffins to BTX 66

Figure III.D.1 Production Cost Comparison of Developing BTX

Technology (100 million pounds per year), 1st Qtr 1994 76

Figure III.D.2 Production Cost Comparison of Developing BTX

Technology (700 million pounds per year), 1st Qtr 1994 77

Figure III.D.3 Developing BTX Technology - Sensitivity to Raw Material Price 78


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