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TRANSCRIPT
Chemicals from Acetylene: Back to the Future?
June 2007
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This report was prepared by Nexant, Inc (“Nexant”) and is part of the Nexant's ChemSystems Topical Report. Except where specifically stated otherwise in this Report, the information contained herein is prepared on the basis of information that is publicly available, and contains no confidential third party technical information to the best knowledge of Nexant. Aforesaid information has not been independently verified or otherwise examined to determine its accuracy, completeness or financial feasibility. Neither NEXANT, Subscriber nor any person acting on behalf of either assumes any liabilities with respect to the use of or for damages resulting from the use of any information contained in this Report. Nexant does not represent or warrant that any assumed conditions will come to pass.
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Chemicals from Acetylene: Back to the Future?
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Contents Section Page 1 Executive Summary ................................................................................................. 1-1
1.1 OVERVIEW .................................................................................................. 1-1
1.2 COMPARISON BASIS................................................................................. 1-1
1.3 ECONOMIC COMPARISONS..................................................................... 1-3
1.3.1 Acetylene ........................................................................................... 1-3
1.3.2 Same Capacity ................................................................................... 1-3
1.3.3 Acetylene Derivatives........................................................................ 1-5
1.3.4 Regional comparisons........................................................................ 1-29
1.4 SENSITIVITY ............................................................................................... 1-39
1.4.1 Ethylene ............................................................................................. 1-39
2 Introduction.............................................................................................................. 2-1
2.1 OVERVIEW .................................................................................................. 2-1
2.1.1 Overall Value Premise ....................................................................... 2-1
2.2 BACKGROUND ........................................................................................... 2-2
2.3 ABSTRACT................................................................................................... 2-5
3 Approach and Methodology.................................................................................... 3-1
3.1 APPROACH .................................................................................................. 3-1
3.1.1 Technology and Economic Evaluation .............................................. 3-1
3.1.2 Commercial Evaluation ..................................................................... 3-1
4 Acetylene Technology .............................................................................................. 4-1
4.1 PARTIAL OXIDATION PROCESS............................................................. 4-1
4.1.1 Background ........................................................................................ 4-1
4.1.2 Process Design ................................................................................... 4-3
4.1.3 Process Description............................................................................ 4-4
4.2 CALCIUM CARBIDE PROCESS ................................................................ 4-11
4.2.1 Background ........................................................................................ 4-11
4.2.2 Process Design ................................................................................... 4-12
4.2.3 China Perspective............................................................................... 4-24
4.3 ACETYLENE RECOVERY FROM STEAM CRACKERS ........................ 4-28
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4.3.1 Background ........................................................................................ 4-28
4.3.2 Process Design ................................................................................... 4-29
4.4 ELECTRIC ARC TECHNOLOGY............................................................... 4-33
4.4.1 Background ........................................................................................ 4-33
4.4.2 Process Design - Hüls Electric Arc Process ...................................... 4-33
5 Commercial Chemicals from Acetylene................................................................. 5-1
5.1 ACRYLIC ACID ........................................................................................... 5-1
5.1.1 Process Chemistry.............................................................................. 5-1
5.1.2 Mass Balance and Integration............................................................ 5-2
5.2 ACRYLONITRILE........................................................................................ 5-5
5.2.1 Process Description............................................................................ 5-5
5.3 BDO VIA ACETYLENE/FORMALDEHYDE (REPPE CONCEPT) ......... 5-9
5.3.1 Process Chemistry.............................................................................. 5-9
5.3.2 Process Description............................................................................ 5-11
5.4 VINYL ACETATE MONOMER.................................................................. 5-15
5.4.1 Chemistry........................................................................................... 5-15
5.4.2 Description......................................................................................... 5-15
5.5 VINYL CHLORIDE MONOMER................................................................ 5-18
5.6 CHLOROPRENE MONOMER..................................................................... 5-21
5.6.1 Chemistry........................................................................................... 5-21
5.6.2 Process Description............................................................................ 5-21
5.7 ISOPRENE .................................................................................................... 5-25
5.7.1 Ethynylation....................................................................................... 5-27
5.7.2 Selective Hydrogenation.................................................................... 5-27
5.7.3 Purification......................................................................................... 5-27
6 Non-Commercial Chemicals from Acetylene ........................................................ 6-1
6.1 ETHYLENE................................................................................................... 6-1
6.1.1 Large-Scale Acetylene Hydrogenation .............................................. 6-1
6.1.2 Ethylene from Natural Gas via Acetylene ......................................... 6-4
6.1.3 Ethylene via Acetylene Hydrogenation ............................................. 6-6
6.2 BENZENE ..................................................................................................... 6-9
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6.2.1 Chemistry........................................................................................... 6-9
7 Chemicals from Conventional Feedstock Technologies ....................................... 7-1
7.1 ACRYLIC ACID ........................................................................................... 7-1
7.1.1 Overview............................................................................................ 7-1
7.1.2 Propylene Based Processes for Crude Acrylic Acid.......................... 7-1
7.1.3 Environmental Treatment .................................................................. 7-16
7.1.4 Metallurgy.......................................................................................... 7-19
7.1.5 GLACIAL ACRYLIC ACID............................................................. 7-20
7.2 ACRYLONITRILE........................................................................................ 7-22
7.2.1 Propylene Ammoxidation .................................................................. 7-22
7.2.2 Propane Ammoxidation ..................................................................... 7-28
7.3 BDO/THF ...................................................................................................... 7-34
7.3.1 Davy Process Technology - 1,4-Butanediol Process using Maleic Anhydride .......................................................................................... 7-34
7.3.2 Eurodiol (Now BASF) Concept Based on Maleic Anhydride........... 7-44
7.3.3 BP/Lurgi GEMINOX® from n-Butane via Maleic Acid .................. 7-50
7.4 VINYL ACETATE MONOMER.................................................................. 7-54
7.4.1 Gas phase ethylene-based processes.................................................. 7-54
7.4.2 BP Leap Process ................................................................................ 7-62
7.4.3 Celanese VAntage Process ................................................................ 7-66
7.4.4 Recent Patents (Ethylene-Based Processes) ...................................... 7-67
7.5 VINYL CHLORIDE MONOMER................................................................ 7-69
7.5.1 Ethylene-based VCM Process............................................................ 7-69
7.6 ISOPRENE .................................................................................................... 7-80
7.6.1 Extraction from the Steam Cracker C5 Stream .................................. 7-80
7.7 ETHYLENE................................................................................................... 7-88
7.7.1 Steam Cracking Technology Overview ............................................. 7-88
7.7.2 Feedstock Selection ........................................................................... 7-89
7.7.3 Process Description............................................................................ 7-90
7.8 BENZENE ..................................................................................................... 7-92
7.8.1 Introduction........................................................................................ 7-92
7.8.2 Catalytic Reforming........................................................................... 7-94
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7.8.3 Pyrolysis Gasoline ............................................................................. 7-113
7.8.4 Aromatics Extraction ......................................................................... 7-115
7.8.5 Dalkylation processes ........................................................................ 7-127
7.8.6 Toluene Disproportionation ............................................................... 7-134
8 Economic Bases ........................................................................................................ 8-1
8.1 COMPARISON BASIS................................................................................. 8-1
8.2 COST OF PRODUCTION WORKSHEETS................................................. 8-3
8.2.1 Transfer Costs .................................................................................... 8-3
8.2.2 Economic Basis.................................................................................. 8-3
8.2.3 Capital and Operating Costs .............................................................. 8-3
8.2.4 Inside Battery Limits Investment....................................................... 8-5
8.2.5 Outside Battery Limits Investment .................................................... 8-6
8.2.6 Contractor Charges ............................................................................ 8-7
8.2.7 Project Contingency Allowance ........................................................ 8-7
8.2.8 Other Project Costs ............................................................................ 8-8
8.2.9 Working Capital................................................................................. 8-9
8.2.10 Shipping Costs and Tariffs................................................................. 8-9
9 Acetylene Economics ............................................................................................... 9-1
9.1 PARTIAL OXIDATION ............................................................................... 9-1
9.2 CALCIUM CARBIDE................................................................................... 9-5
9.3 ACETYLENE RECOVERY FROM STEAM CRACKERS ........................ 9-9
9.4 ELECTRIC ARC TECHNOLOGY............................................................... 9-11
9.5 ECONOMIC COMPARISON....................................................................... 9-13
9.5.1 Base Economics ................................................................................. 9-13
9.5.2 Same Capacity ................................................................................... 9-13
10 Chemicals from Acetylene Economics ................................................................... 10-1
10.1 UNITED STATES......................................................................................... 10-1
10.1.1 Acrylic Acid....................................................................................... 10-1
10.1.2 Acrylonitrile....................................................................................... 10-3
10.1.3 BDO/THF .......................................................................................... 10-5
10.1.4 Chloroprene........................................................................................ 10-6
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10.1.5 Isoprene.............................................................................................. 10-8
10.1.6 Vinyl Acetate Monomer .................................................................... 10-10
10.1.7 Vinyl chloride monomer .................................................................... 10-12
10.1.8 Ethylene ............................................................................................. 10-13
10.1.9 Benzene.............................................................................................. 10-15
10.2 CHINA........................................................................................................... 10-17
10.2.1 Acrylic Acid....................................................................................... 10-17
10.2.2 Acrylonitrile....................................................................................... 10-19
10.2.3 BDO/THF .......................................................................................... 10-21
10.2.4 Chloroprene........................................................................................ 10-22
10.2.5 Isoprene.............................................................................................. 10-24
10.2.6 Vinyl Acetate Monomer .................................................................... 10-26
10.2.7 Vinyl chloride monomer .................................................................... 10-28
10.2.8 Ethylene ............................................................................................. 10-29
10.2.9 Benzene.............................................................................................. 10-31
11 Chemicals from Conventional Feedstocks Economics ......................................... 11-1
11.1 UNITED STATES......................................................................................... 11-1
11.1.1 Acrylic Acid....................................................................................... 11-1
11.1.2 Acrylonitrile....................................................................................... 11-2
11.1.3 BDO/THF .......................................................................................... 11-4
11.1.4 Isoprene.............................................................................................. 11-5
11.1.5 Vinyl Acetate Monomer .................................................................... 11-7
11.1.6 Vinyl Chloride Monomer................................................................... 11-8
11.1.7 Ethylene ............................................................................................. 11-10
11.1.8 Benzene.............................................................................................. 11-12
11.2 CHINA........................................................................................................... 11-14
11.2.1 Acrylic Acid....................................................................................... 11-14
11.2.2 Acrylonitrile....................................................................................... 11-15
11.2.3 BDO/THF .......................................................................................... 11-17
11.2.4 Isoprene.............................................................................................. 11-18
11.2.5 Vinyl Acetate Monomer .................................................................... 11-20
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11.2.6 Vinyl Chloride Monomer................................................................... 11-21
11.2.7 Ethylene ............................................................................................. 11-23
11.2.8 Benzene.............................................................................................. 11-25
12 Regional Economics and Comparisons .................................................................. 12-1
12.1 ECONOMICS COMPARISONS................................................................... 12-1
12.1.1 United States ...................................................................................... 12-1
12.1.2 China .................................................................................................. 12-10
12.1.3 Eastern Europe ................................................................................... 12-19
12.2 REGIONAL COMPARISONS...................................................................... 12-27
12.2.1 VCM .................................................................................................. 12-27
12.2.2 VAM .................................................................................................. 12-31
12.2.3 Benzene.............................................................................................. 12-35
12.2.4 Ethylene ............................................................................................. 12-39
12.3 SENSITIVITY ............................................................................................... 12-45
12.3.1 Ethylene ............................................................................................. 12-45
13 Markets ..................................................................................................................... 13-1
13.1 ETHYLENE................................................................................................... 13-1
13.1.1 Global................................................................................................. 13-1
13.1.2 Supply ................................................................................................ 13-3
13.1.3 Supply, Demand and Trade................................................................ 13-4
13.1.4 North America ................................................................................... 13-4
13.2 WESTERN EUROPE .................................................................................... 13-12
13.2.1 Ethylene ............................................................................................. 13-12
13.3 ASIA PACIFIC.............................................................................................. 13-18
13.3.1 Ethylene ............................................................................................. 13-18
13.4 BENZENE ..................................................................................................... 13-28
13.4.1 Global................................................................................................. 13-28
13.4.2 North America ................................................................................... 13-34
13.4.3 Western Europe.................................................................................. 13-41
13.4.4 Asia Pacific ........................................................................................ 13-49
13.5 VCM .............................................................................................................. 13-59
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13.5.1 Global................................................................................................. 13-59
13.5.2 North America ................................................................................... 13-63
13.5.3 Western Europe.................................................................................. 13-68
13.5.4 Asia Pacific ........................................................................................ 13-70
13.6 VINYL ACETATE........................................................................................ 13-77
13.6.1 Applications ....................................................................................... 13-77
13.6.2 Demand .............................................................................................. 13-77
13.6.3 Capacity ............................................................................................. 13-79
13.6.4 Supply/Demand/Trade ....................................................................... 13-80
13.7 ACRYLONITRILE........................................................................................ 13-89
13.7.1 End Uses ............................................................................................ 13-89
13.7.2 Global Overview................................................................................ 13-90
13.7.3 Americas ............................................................................................ 13-93
13.7.4 Europe/Middle East/Africa ................................................................ 13-96
13.7.5 Asia Pacific ........................................................................................ 13-99
13.8 ACRYLIC ACID ........................................................................................... 13-103
13.8.1 Global Overview................................................................................ 13-103
13.8.2 Consumption ...................................................................................... 13-103
13.8.3 Supply ................................................................................................ 13-105
13.8.4 Supply, Demand and Trade................................................................ 13-106
13.8.5 North America ................................................................................... 13-107
13.8.6 Western Europe.................................................................................. 13-112
13.8.7 Asia Pacific ........................................................................................ 13-115
13.9 ACETYLENE CAPACITY........................................................................... 13-121
13.9.1 United States ...................................................................................... 13-121
13.9.2 Western Europe.................................................................................. 13-121
13.9.3 Asia Pacific ........................................................................................ 13-122
14 Bibliography ............................................................................................................. 14-1
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Figure Page 1.1 Comparison of Acetylene Costs of Production (Designated Capacities,
USGC, 2006).............................................................................................................. 1-3
1.2 Comparison of Acetylene Costs of Production (All at 50 KTA, USGC, 2006) ........ 1-4
1.3 Comparison of Acetylene Costs of Production.......................................................... 1-5
1.4 Acrylic Acid Cost of Production Comparison, U.S. .................................................. 1-6
1.5 Acrylonitrile Cost of Production Comparison, U.S. .................................................. 1-7
1.6 BDO Cost of Production Comparison, U.S. .............................................................. 1-8
1.7 Isoprene Cost of Production Comparison, U.S. ......................................................... 1-9
1.8 Vinyl Acetate Cost of Production Comparison, U.S. ................................................ 1-10
1.9 Vinyl Chloride Cost of Production Comparison, U.S................................................ 1-11
1.10 Ethylene Cost of Production Comparison, U.S. ........................................................ 1-12
1.11 Benzene Cost of Production Comparison, U.S. ......................................................... 1-13
1.12 Acrylic Acid Cost of Production Comparison, China ............................................... 1-14
1.13 Acrylonitrile Cost of Production Comparison, China................................................ 1-15
1.14 BDO Cost of Production Comparison, China............................................................ 1-16
1.15 Isoprene Cost of Production Comparison, China ...................................................... 1-17
1.16 Vinyl Acetate Cost of Production Comparison, China.............................................. 1-18
1.17 Vinyl Chloride Cost of Production Comparison, China ............................................ 1-19
1.18 Ethylene Cost of Production Comparison, China ...................................................... 1-20
1.19 Benzene Cost of Production Comparison, China ...................................................... 1-21
1.20 Acrylic Acid Cost of Production Comparison, Eastern Europe ................................ 1-22
1.21 Acrylonitrile Cost of Production Comparison, Eastern Europe................................. 1-23
1.22 BDO Cost of Production Comparison, Eastern Europe............................................. 1-24
1.23 Isoprene Cost of Production Comparison, Eastern Europe ....................................... 1-25
1.24 Vinyl Acetate Cost of Production Comparison, Eastern Europe............................... 1-26
1.25 Vinyl Chloride Cost of Production Comparison, Eastern Europe ............................. 1-27
1.26 Ethylene Cost of Production Comparison, Eastern Europe ....................................... 1-28
1.27 Benzene Cost of Production Comparison, Eastern Europe ....................................... 1-29
1.28 VCM Delivered Cost Comparison, U.S., 2006.......................................................... 1-30
1.29 VCM Delivered Cost Comparison, Western Europe, 2006....................................... 1-31
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1.30 VAM Delivered Cost Comparison, U.S., 2006 ......................................................... 1-32
1.31 VAM Delivered Cost Comparison, Western Europe, 2006....................................... 1-33
1.32 Benzene Delivered Cost Comparison, U.S., 2006 ..................................................... 1-34
1.33 Benzene Delivered Cost Comparison, Western Europe, 2006 .................................. 1-35
1.34 Ethylene Delivered Cost Comparison, U.S., 2006..................................................... 1-36
1.35 Ethylene Delivered Cost Comparison, Western Europe, 2006.................................. 1-37
1.36 Ethylene Delivered Cost Comparison, China, 2006 .................................................. 1-38
1.37 Ethylene Delivered Cost Comparison (Higher Acetylene Route Capex), U.S., 2006 1-39
1.38 Ethylene Delivered Cost Comparison (Higher Acetylene Route Capex), Western Europe, 2006................................................................................................ 1-40
1.39 Ethylene Delivered Cost Comparison (Higher Acetylene Route Capex), China, 2006 ................................................................................................................ 1-41
2.1 Acetylene Products .................................................................................................... 2-3
2.2 Commercial Derivatives ............................................................................................ 2-4
4.1 Burner Characteristics................................................................................................ 4-2
4.2 BASF Partial Oxidation Acetylene Process Reaction and Separation......................... 4-5
4.3 BASF Partial Oxidation Acetylene Process Solvent Regeneration ............................. 4-6
4.4 BASF Acetylene Burner ............................................................................................ 4-7
4.5 Improved Burner Block ............................................................................................. 4-10
4.6 Calcium Carbide Acetylene Process............................................................................. 4-13
4.7 Calcium Carbide Block Diagram.............................................................................. 4-20
4.8 First and Primary Reactor .......................................................................................... 4-21
4.9 Second Reactor .......................................................................................................... 4-22
4.10 Linde Acetylene Recovery Technology Scheme....................................................... 4-30
4.11 Electric Arc - Process................................................................................................. 4-35
4.12 Electric Arc Purification ............................................................................................ 4-36
5.1 Mass Balance for Crude Acrylic Acid from Acetylene ............................................. 5-4
5.2 American Cyanamide Design .................................................................................... 5-6
5.3 Synthesis of 1,4-Butynediol from Acetylene and Formaldehyde............................ 5-12
5.4 Two Step Hydrogenation of 1,4-Butynediol to 1,4-Butanediol................................. 5-14
5.5 Vinyl Acetate via Acetylene (Wacker Process)......................................................... 5-16
5.6 VCM via C2H2/HCl.................................................................................................... 5-19
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5.7 Monovinylacetylene Process Flow Diagram ............................................................. 5-22
5.8 Chloroprene Process Flow Diagram .......................................................................... 5-24
5.9 Snamprogetti Route to Isoprene................................................................................. 5-26
6.1 Ethylene Process Scheme 1 ....................................................................................... 6-4
6.2 Ethylene Process Scheme 2 ....................................................................................... 6-5
6.3 Integrated Reactor: Thermal Pyrolysis Coupled with In-situ Hydrogenation ........... 6-8
6.4 Cyclotrimerization Reaction ...................................................................................... 6-11
6.5 Reaction Mechanism.................................................................................................. 6-13
6.6 Process Flow Diagram via Trimerization .................................................................. 6-14
7.1 Simplified View of Propylene to Acrolein Reaction Mechanism ............................. 7-2
7.2 Oxidation Reactor Schematic .................................................................................... 7-7
7.3 Oxidation with Tandem Reactors (one Line Only).................................................... 7-9
7.4 Simplified Water Quench Separation Train............................................................... 7-12
7.5 Solvent Quench Separation Train .............................................................................. 7-15
7.6 Simplified Incinerator Design.................................................................................... 7-17
7.7 Simplified Wastewater Treatment System Design .................................................... 7-18
7.8 Acrylonitrile via Propylene Ammoxidation Ineos/BP Process................................ 7-23
7.9 Integrated Acrylonitrile Wastewater Treatment System............................................ 7-26
7.10 BP Ammonia Recovery and Recycle......................................................................... 7-31
7.11 Simplified Worldscale Crude Maleic Anhydride Production from Normal Butane.. 7-39
7.12 Davy Process Maleic Anhydride Esterification and Hydrogenation ......................... 7-41
7.13 Davy Process Separation and Purification................................................................. 7-43
7.14 Schematic View of Eurodiol 1,4-Butanediol and Derivatives Process (Illustrative). 7-45
7.15 PB Lurgi Geminox Fluid Bed Maleic Acid Production............................................. 7-51
7.16 BP Lurgi Geminox Maleic Acid Conversion to Butanediol ...................................... 7-53
7.17 VAM/Ethylene Process Reaction Mechanism........................................................... 7-55
7.18 Vapor Phase, Fixed-Bed Vinyl Acetate from Ethylene Process................................ 7-57
7.19 BP Leap Vinyl Acetate Process ................................................................................. 7-64
7.20 VCM via C2H4/Cl2 Chlroindation/Oxychlorination Process...................................... 7-71
7.21 EDC/VCM Balanced Plant Block Flow Diagram (Oxyvinyls Process).................... 7-72
7.22 EDC/VCM Balanced Plant Block Diagram (EVC Process)...................................... 7-73
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7.23 EVC Chlorinated Byproduct Recycle Process........................................................... 7-78
7.24 Simplified Flow Diagram for the Nippon Zeon GPI Process .................................... 7-84
7.25 Isoprene Complex with DCPD and Piperylene and C5 Olefin Co-Products ............. 7-87
7.26 Semiregenerative Reformer Process Flow Diagram.................................................. 7-104
7.27 Continuous Catalytic Reforming Process Flow Diagram.......................................... 7-106
7.28 Cyclic Catalytic Reformer Process Flow Diagram.................................................... 7-107
7.29 Naphtha Hydrotreater Process Flow Diagram ........................................................... 7-109
7.30 Effect of Steam Cracker Feedstock on Aromatics Yield ........................................... 7-114
7.31 Effect of Severity on Aromatics Yields for a Naphtha Feed ..................................... 7-114
7.32 Shell/UOP Sulfonate Process..................................................................................... 7-118
7.33 Aromatics Fractionation Section................................................................................ 7-120
7.34 BTX Recovery Block Flow Diagram ........................................................................ 7-122
7.35 BTX Recovery Investment (ISBL) Versus Capacity................................................. 7-124
7.36 Morphylane Extractive Distillation Process Flow Diagram ...................................... 7-126
7.37 Detol Unit Simplified Flowsheet ............................................................................... 7-130
7.38 Litol Unit Simplified Flowsheet ................................................................................ 7-133
7.39 Toluene Disproportionation Typical Flowsheet ........................................................ 7-136
9.1 Comparison of Costs of Production (Designated Capacities).................................... 9-13
9.2 Comparison of Costs of Production (All at 50 KTA) ................................................ 9-14
9.3 Comparison of Costs of Production........................................................................... 9-15
12.1 Acrylic Acid Cost of Production Comparison, U.S. .................................................. 12-1
12.2 Acrylonitrile Cost of Production Comparison, U.S. .................................................. 12-2
12.3 BDO Cost of Production Comparison, U.S. .............................................................. 12-3
12.4 Isoprene Cost of Production Comparison, U.S. ......................................................... 12-4
12.5 Vinyl Acetate Cost of Production Comparison, U.S. ................................................ 12-5
12.6 Vinyl Chloride Cost of Production Comparison, U.S................................................ 12-6
12.7 Ethylene Cost of Production Comparison, U.S. ........................................................ 12-7
12.8 Benzene Cost of Production Comparison, U.S. ......................................................... 12-8
12.9 Acrylic Acid Cost of Production Comparison, China ............................................... 12-10
12.10 Acrylonitrile Cost of Production Comparison, China............................................. 12-11
12.11 BDO Cost of Production Comparison, China......................................................... 12-12
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12.12 Isoprene Cost of Production Comparison, China ................................................... 12-13
12.13 Vinyl Acetate Cost of Production Comparison, China........................................... 12-14
12.14 Vinyl Chloride Cost of Production Comparison, China ......................................... 12-15
12.15 Ethylene Cost of Production Comparison, China ................................................... 12-16
12.16 Benzene Cost of Production Comparison, China ................................................... 12-17
12.17 Acrylic Acid Cost of Production Comparison, Eastern Europe ............................. 12-19
12.18 Acrylonitrile Cost of Production Comparison, Eastern Europe.............................. 12-20
12.19 BDO Cost of Production Comparison, Eastern Europe.......................................... 12-21
12.20 Isoprene Cost of Production Comparison, Eastern Europe .................................... 12-22
12.21 Vinyl Acetate Cost of Production Comparison, Eastern Europe............................ 12-23
12.22 Vinyl Chloride Cost of Production Comparison, Eastern Europe .......................... 12-24
12.23 Ethylene Cost of Production Comparison, Eastern Europe .................................... 12-25
12.24 Benzene Cost of Production Comparison, Eastern Europe .................................... 12-26
12.25 VCM Delivered Cost Comparison, U.S., 2006....................................................... 12-27
12.26 VCM Delivered Cost Comparison, U.S., 2010....................................................... 12-28
12.27 VCM Delivered Cost Comparison, U.S., 2015....................................................... 12-28
12.28 VCM Delivered Cost Comparison, Western Europe, 2006.................................... 12-29
12.29 VCM Delivered Cost Comparison, Western Europe, 2010.................................... 12-30
12.30 VCM Delivered Cost Comparison, Western Europe, 2015.................................... 12-30
12.31 VAM Delivered Cost Comparison, U.S., 2006 ...................................................... 12-31
12.32 VAM Delivered Cost Comparison, U.S., 2010 ...................................................... 12-32
12.33 VCM Delivered Cost Comparison, U.S., 2015....................................................... 12-32
12.34 VAM Delivered Cost Comparison, Western Europe, 2006.................................... 12-33
12.35 VAM Delivered Cost Comparison, Western Europe, 2010.................................... 12-34
12.36 VAM Delivered Cost Comparison, Western Europe, 2015.................................... 12-34
12.37 Benzene Delivered Cost Comparison, U.S., 2006 .................................................. 12-35
12.38 Benzene Delivered Cost Comparison, U.S., 2010 .................................................. 12-36
12.39 Benzene Delivered Cost Comparison, U.S., 2015 .................................................. 12-36
12.40 Benzene Delivered Cost Comparison, Western Europe, 2006 ............................... 12-37
12.41 Benzene Delivered Cost Comparison, Western Europe, 2010 ............................... 12-38
12.42 Benzene Delivered Cost Comparison, Western Europe, 2015 ............................... 12-38
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12.43 Ethylene Delivered Cost Comparison, U.S., 2006.................................................. 12-39
12.44 Ethylene Delivered Cost Comparison, U.S., 2010.................................................. 12-40
12.45 Ethylene Delivered Cost Comparison, U.S., 2015.................................................. 12-40
12.46 Ethylene Delivered Cost Comparison, Western Europe, 2006............................... 12-41
12.47 Ethylene Delivered Cost Comparison, Western Europe, 2010............................... 12-42
12.48 Ethylene Delivered Cost Comparison, Western Europe, 2015............................... 12-42
12.49 Ethylene Delivered Cost Comparison, China, 2006 ............................................... 12-43
12.50 Ethylene Delivered Cost Comparison, China, 2010 ............................................... 12-44
12.51 Ethylene Delivered Cost Comparison, China, 2015 ............................................... 12-44
12.52 Ethylene Delivered Cost Comparison (higher acetylene route capex), U.S., 2006 12-45
12.53 Ethylene Delivered Cost Comparison (higher acetylene route capex), U.S., 2010 12-46
12.54 Ethylene Delivered Cost Comparison (higher acetylene route capex), U.S., 2015 12-47
12.55 Ethylene Delivered Cost Comparison (higher acetylene route capex), Western Europe, 2006............................................................................................. 12-48
12.56 Ethylene Delivered Cost Comparison (higher acetylene route capex), Western Europe, 2010............................................................................................. 12-49
12.57 Ethylene Delivered Cost Comparison (higher acetylene route capex), Western Europe, 2015............................................................................................. 12-49
12.58 Ethylene Delivered Cost Comparison (higher acetylene route capex), China, 2006............................................................................................................. 12-50
12.59 Ethylene Delivered Cost Comparison (Higher Acetylene Route Capex), China, 2010............................................................................................................. 12-51
12.60 Ethylene Delivered Cost Comparison (higher acetylene route capex), China, 2015............................................................................................................. 12-51
13.1 Global Ethylene Demand, 2006................................................................................. 13-1
13.2 Regional Ethylene Capacity....................................................................................... 13-3
13.3 North American Ethylene Consumption, 2006.......................................................... 13-6
13.4 West European Ethylene Consumption, 2006 ........................................................... 13-12
13.5 Asia Pacific Ethylene Consumption, 2006 ................................................................ 13-21
13.6 Global Benzene Demand, 2005 ................................................................................. 13-29
13.7 Global Benzene Firm Capacity Additions ................................................................. 13-31
13.8 Regional Benzene Capacity ....................................................................................... 13-32
13.9 Global Benzene Net Trade......................................................................................... 13-33
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13.10 North America Benzene Consumption, 2006 ......................................................... 13-35
13.11 Western European Benzene Consumption - 2006 .................................................. 13-42
13.12 Asia Pacific Benzene Consumption - 2006 ............................................................ 13-50
13.13 Regional VCM Consumption ................................................................................. 13-60
13.14 VCM Production Basis ........................................................................................... 13-60
13.15 Regional VCM Capacity......................................................................................... 13-61
13.16 Regional VCM Net Exports/(Imports).................................................................... 13-63
13.17 Global VAM Demand by End Use, 2006 ............................................................... 13-78
13.18 VAM Demand Growth Rate by Region.................................................................. 13-78
13.19 VAM Capacity by Region ...................................................................................... 13-79
13.20 VAM Capacity by Company, 2005 ........................................................................ 13-80
13.21 Global VAM Trade Balance ................................................................................... 13-86
13.22 Global Acrylonitrile Consumption ......................................................................... 13-90
13.23 Global Acrylonitrile Consumption Pattern, 2006 ................................................... 13-91
13.24 Global Acrylonitrile Capacity Share by Company, 2010 ....................................... 13-92
13.25 Americas Acrylonitrile Consumption Pattern, 2006............................................... 13-93
13.26 Americas Acrylonitrile Capacity Share by Company, 2010................................... 13-95
13.27 EMEA Acrylonitrile Consumption Pattern, 2006................................................... 13-96
13.28 EMEA Acrylonitrile Capacity Share by Company, 2010....................................... 13-98
13.29 Asia Pacific Acrylonitrile Consumption Pattern, 2006........................................... 13-99
13.30 Asia Pacific Acrylonitrile Capacity Share by Company, 2010............................... 13-101
13.31 Global Acrylic Acid Capacity Addition ................................................................. 13-105
13.32 Global Acrylic Acid Capacity Total ....................................................................... 13-106
13.33 North American Acrylic Acid Consumption, 2006 ................................................ 13-109
13.34 West European Acrylic Acid Consumption, 2006.................................................. 13-113
13.35 Asia Pacific Acrylic Acid Consumption, 2006....................................................... 13-116
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Table Page 1.1 Acetylene Economic Basis (Leader Capacity) .......................................................... 1-1
1.2 Acetylene Derivative Chemicals and Conventional Equivalents .............................. 1-2
1.3 Derivative Capacities ................................................................................................. 1-2
2.1 U.S. Production of Chemicals from Acetylene.......................................................... 2-6
4.1 Typical Composition of BASF Cracked Gas with Various Feeds............................. 4-8
4.2 Typical Composition of BASF Product Acetylene with Natural Gas Feed............... 4-9
4.3 Analysis of Coal, as Received ................................................................................... 4-12
4.4 Limestone Feed Composition, Dry Basis .................................................................. 4-14
4.5 Lime Feed Composition to Carbide Furnace, Dry Basis ........................................... 4-14
4.6 Coke Composition, Dry Basis.................................................................................... 4-15
4.7 Purified Coke Oven Gas, Dry Basis .......................................................................... 4-16
4.8 Carbide Furnace Offgas, Dry Basis ........................................................................... 4-16
4.9 Impurities in Carbide Acetylene ................................................................................ 4-18
4.10 Production of Acetylene for Various Steam Cracker Feeds ...................................... 4-28
4.11 Utility Consumption.................................................................................................... 4-32
4.12 Material Balance ........................................................................................................ 4-32
4.13 Distribution of Electrical Energy to the Arc ............................................................... 4-34
4.14 Average Cracked Gas Composition............................................................................ 4-34
5.1 Raw Material Yields .................................................................................................. 5-8
5.2 Typical VAM Product Specifications........................................................................ 5-17
5.3 Acetylene Based Isoprene Plant Performance ........................................................... 5-25
6.1 Experiment 1 Results ................................................................................................. 6-2
6.2 Experiment 2 Results ................................................................................................. 6-2
6.3 Experiment 7 Results ................................................................................................. 6-2
6.4 Reaction Yields.......................................................................................................... 6-11
6.5 Acetylenes Used and Products Obtained ................................................................... 6-12
7.1 Physical Properties of Acrylonitrile........................................................................... 7-25
7.2 Experimental Results from Asahi Kasei Patent ......................................................... 7-28
7.3 Standard Oil Patent Examples ................................................................................... 7-30
7.4 Experimental Results from Standard Oil Patent ........................................................ 7-33
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7.5 Eurodiol Butanediol Process...................................................................................... 7-46
7.6 Butanediol from Maleic Anhydride ........................................................................... 7-47
7.7 Analysis of VAM Product from the Bayer/Hoechst Ethylene-Based Process .......... 7-59
7.8 Advantages Offered by BP Leap Process and Celanese Vantage Process ................ 7-62
7.9 Selected Results from Fluid-Bed VAM Catalysts ..................................................... 7-67
7.10 VAM Selectivity for Fixed-Bed Pd/Au/K Catalyst ................................................... 7-68
7.11 C5 Yields from Naphtha Cracking ............................................................................. 7-80
7.12 C5 Yields from Other Cracking Feedstocks............................................................... 7-81
7.13 Relative Volatilities of C5 Components in Different Solvents¹ ................................. 7-82
7.14 Typical BTX Composition from Pygas and Reformate............................................. 7-93
7.15 Basic Relationships in Catalytic Reforming .............................................................. 7-96
7.16 Typical Yields of UOP’s Reforming Processes......................................................... 7-111
7.17 Typical Yields of IFP’s Reforming Processes ........................................................... 7-111
7.18 Typical Utilities of UOP and IFP Reforming Processes............................................ 7-112
7.19 Extractive Distillation: Effect of n-Formylmorpholine Solvent on Boiling Temperatures at One Atmosphere, °F........................................................................ 7-116
7.20 Properties of Extraction Distillation Solvents............................................................ 7-116
7.21 BTX Recovery Material Balance (Pygas).................................................................. 7-123
7.22 BTX Recovery Material Balance (Reformate) .......................................................... 7-123
7.23 USGC BTX Recovery ISBL, from Pygas.................................................................. 7-124
7.24 Benzene Product Quality from the Octenar Process.................................................. 7-127
7.25 Hydrodealkylation Processes ..................................................................................... 7-128
8.1 Acetylene Economic Basis (Leader Capacity) .......................................................... 8-1
8.2 Basis for Capital Costs, 215 KTA.............................................................................. 8-2
8.3 Acetylene Derivative Chemicals and Conventional Equivalents .............................. 8-2
8.4 Derivative Capacities ................................................................................................. 8-3
8.5 Regional Prices .......................................................................................................... 8-4
8.6 Regional Utility and Wage Unit Costs....................................................................... 8-5
8.7 ISBL Capital Investment Location Factors, Relative to USGC ................................ 8-5
8.8 Shipping Costs and Tariffs......................................................................................... 8-10
9.1 Cost of Production: Syngas for Methanol Process: Autothermal Reforming, Large-Scale, SN=2..................................................................................................... 9-2
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9.2 Cost of Production: Acetylene Process: Partial Oxidation, Chemical Value Syngas ............................................................................................. 9-3
9.3 Cost of Production: Acetylene Process: Partial Oxidation, Heat Value Syngas........ 9-4
9.4 Cost of Production: Coke Process: Coal.................................................................... 9-6
9.5 Cost of Production: Calcium Carbide Process: Closed Furnace Design ................... 9-7
9.6 Cost of Production: Acetylene Process: Calcium Carbide ........................................ 9-8
9.7 Cost of Production: Acetylene Process: Ethylene Byproduct.................................... 9-10
9.8 Cost of Production: Acetylene Process: Electric Arc ................................................ 9-12
10.1 Cost of Production Estimate for: Acrylic Acid.......................................................... 10-2
10.2 Cost of Production Estimate for: Acrylonitrile.......................................................... 10-4
10.3 Cost of Production Estimate for: 1,4-BDO................................................................ 10-5
10.4 Cost of Production Estimate for: Chloroprene........................................................... 10-7
10.5 Cost of Production Estimate for: Isoprene................................................................. 10-9
10.6 Cost of Production Estimate for: VAM ..................................................................... 10-11
10.7 Cost of Production Estimate for: VCM ..................................................................... 10-12
10.8 Cost of Production Estimate for: Ethylene ................................................................ 10-14
10.9 Cost of Production Estimate for: Benzene................................................................. 10-16
10.10 Cost of Production Estimate for: Acrylic Acid....................................................... 10-18
10.11 Cost of Production Estimate for: Acrylonitrile....................................................... 10-20
10.12 Cost of Production Estimate for: 1,4-BDO............................................................. 10-21
10.13 Cost of Production Estimate for: Chloroprene........................................................ 10-23
10.14 Cost of Production Estimate for: Isoprene.............................................................. 10-25
10.15 Cost of Production Estimate for: VAM .................................................................. 10-27
10.16 Cost of Production Estimate for: VCM .................................................................. 10-28
10.17 Cost of Production Estimate for: Ethylene ............................................................. 10-30
10.18 Cost of Production Estimate for: Benzene.............................................................. 10-32
11.1 Cost of Production Estimate for: Acrylic Acid.......................................................... 11-1
11.2 Cost of Production Estimate for: Acrylonitrile.......................................................... 11-3
11.3 Cost of Production Estimate for: 1,4-BDO................................................................ 11-4
11.4 Cost of Production Estimate for: Isoprene................................................................. 11-6
11.5 Cost of Production Estimate for: VAM ..................................................................... 11-7
11.6 Cost of Production Estimate for: VCM ..................................................................... 11-9
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11.7 Cost of Production Estimate for: Ethylene ................................................................ 11-11
11.8 Cost of Production Estimate for: Benzene................................................................. 11-13
11.9 Cost of Production Estimate for: Acrylic Acid.......................................................... 11-14
11.10 Cost of Production Estimate for: Acrylonitrile....................................................... 11-16
11.11 Cost of Production Estimate for: 1,4-BDO............................................................. 11-17
11.12 Cost of Production Estimate for: Isoprene.............................................................. 11-19
11.13 Cost of Production Estimate for: VAM .................................................................. 11-20
11.14 Cost of Production Estimate for: VCM .................................................................. 11-22
11.15 Cost of Production Estimate for: Ethylene ............................................................. 11-24
11.16 Cost of Production Estimate for: Benzene.............................................................. 11-26
12.1 Ethylene Route Raw Material Cost Comparison – U.S., 2006.................................. 12-8
12.2 Benzene Route Raw Material Cost Comparison – U.S., 2006 .................................. 12-9
12.3 Ethylene Route Raw Material Cost Comparison – China, 2006 ............................... 12-17
12.4 Benzene Route Raw Material Cost Comparison – China, 2006................................ 12-18
12.5 Ethylene Route Raw Material Cost Comparison – Eastern Europe, 2006 ................ 12-25
12.6 Benzene Route Raw Material Cost Comparison – Eastern Europe, 2006................. 12-26
13.1 Global Ethylene Consumption................................................................................... 13-2
13.2 Regional Ethylene Consumption ............................................................................... 13-2
13.3 Global Ethylene Supply and Demand........................................................................ 13-4
13.4 North America Ethylene Consumption...................................................................... 13-5
13.5 North American Ethylene Consumption.................................................................... 13-6
13.6 Capacities of Ethylene in North America .................................................................. 13-8
13.7 Canada Ethylene Supply, Demand and Trade ........................................................... 13-10
13.8 Mexico Ethylene Supply, Demand and Trade ........................................................... 13-10
13.9 United States Ethylene Supply, Demand and Trade.................................................. 13-11
13.10 North America Ethylene Supply, Demand and Trade ............................................ 13-11
13.11 West European Ethylene Consumption .................................................................. 13-13
13.12 Capacities for Ethylene in Western Europe ............................................................ 13-15
13.13 West European Ethylene Supply/Demand and Trade............................................. 13-18
13.14 Asia Pacific Ethylene Consumption ....................................................................... 13-19
13.15 Asia Pacific Ethylene Consumption ....................................................................... 13-20
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13.16 Capacities of Ethylene in Asia Pacific.................................................................... 13-25
13.17 Asia Pacific Ethylene Supply, Demand and Trade................................................. 13-28
13.18 Global Benzene Consumption ................................................................................ 13-29
13.19 Regional Benzene Consumption............................................................................. 13-30
13.20 Global Benzene Supply and Demand ..................................................................... 13-33
13.21 North America Benzene Consumption ................................................................... 13-35
13.22 North America Benzene Consumption ................................................................... 13-35
13.23 Capacities of Benzene in North America................................................................ 13-37
13.24 Canada Benzene Supply, Demand and Trade......................................................... 13-39
13.25 Mexico Benzene Supply, Demand and Trade......................................................... 13-39
13.26 United States Supply, Demand and Trade .............................................................. 13-40
13.27 North American Benzene Supply, Demand and Trade........................................... 13-40
13.28 West European Benzene Consumption................................................................... 13-42
13.29 Capacities for Benzene in Western Europe ............................................................ 13-45
13.30 West European Benzene Supply/Demand and Trade ............................................. 13-48
13.31 Asia Pacific Benzene Consumption........................................................................ 13-49
13.32 Asia Pacific Benzene Consumption by Country..................................................... 13-51
13.33 Capacities for Benzene in Asia Pacific................................................................... 13-53
13.34 Asia Pacific Benzene Supply/Demand and Trade .................................................. 13-58
13.35 Regional VCM Consumption ................................................................................. 13-59
13.36 Global VCM Supply and Demand.......................................................................... 13-62
13.37 North American VCM Consumption...................................................................... 13-64
13.38 North American VCM Consumption...................................................................... 13-64
13.39 VCM Capacity in North America ........................................................................... 13-65
13.40 Canadian VCM Supply/Demand and Trade ........................................................... 13-66
13.41 Mexican VCM Supply/Demand and Trade ............................................................ 13-66
13.42 United States VCM Supply/Demand and Trade..................................................... 13-67
13.43 North American VCM Supply/Demand and Trade ................................................ 13-67
13.44 West European VCM Consumption ....................................................................... 13-68
13.45 VCM Capacity in Western Europe ......................................................................... 13-69
13.46 West European VCM Supply/Demand and Trade.................................................. 13-70
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13.47 Asia Pacific VCM Consumption ............................................................................ 13-71
13.48 VCM Capacity in Asia Pacific................................................................................ 13-72
13.49 Asia Pacific VCM Supply/Demand and Trade....................................................... 13-76
13.50 Global VAM Capacity Listing by Region, Producer, Location.............................. 13-82
13.51 Major Vinyl Acetate Monomer Capacity Changes................................................. 13-85
13.52 Global VAM Supply/Demand/Trade Summary ..................................................... 13-85
13.53 North American VAM Supply/Demand/Trade....................................................... 13-86
13.54 Western European VAM Supply/Demand/Trade ................................................... 13-87
13.55 Japanese VAM Supply/Demand/Trade................................................................... 13-87
13.56 Other Asia VAM Supply/Demand/Trade ............................................................... 13-88
13.57 Global Acrylonitrile Consumption ......................................................................... 13-90
13.58 Tri-Regional Acrylonitrile Capacities..................................................................... 13-91
13.59 Global Acrylonitrile Supply, Demand and Trade ................................................... 13-92
13.60 Americas Acrylonitrile Consumption ..................................................................... 13-93
13.61 Americas Acrylonitrile Capacity by Producer........................................................ 13-94
13.62 Americas Acrylonitrile Supply, Demand and Trade............................................... 13-95
13.63 EMEA Acrylonitrile Consumption ......................................................................... 13-96
13.64 EMEA Acrylonitrile Capacity by Producer............................................................ 13-97
13.65 EMEA Acrylonitrile Supply, Demand and Trade................................................... 13-98
13.66 Asia Pacific Acrylonitrile Consumption................................................................. 13-99
13.67 Asia Pacific Acrylonitrile Capacity by Producer.................................................... 13-100
13.68 Asia Pacific Acrylonitrile Supply, Demand, and Trade ......................................... 13-102
13.69 Global Acrylic Acid Consumption ......................................................................... 13-104
13.70 Global Acrylic Acid Consumption by Region........................................................ 13-104
13.71 Global Acrylic Acid Supply/Demand and Trade.................................................... 13-106
13.72 North American Acrylic Acid Consumption by Country ....................................... 13-108
13.73 North American Acrylic Acid Consumption .......................................................... 13-108
13.74 Acrylic Acid Capacity in North America ............................................................... 13-110
13.75 Mexican Acrylic Acid Supply/Demand and Trade................................................. 13-111
13.76 United States Acrylic Acid Supply/Demand and Trade ......................................... 13-111
13.77 North American Acrylic Acid Supply/Demand and Trade..................................... 13-112
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13.78 West European Acrylic Acid Consumption............................................................ 13-113
13.79 Acrylic Acid Capacity in Western Europe.............................................................. 13-114
13.80 West European Acrylic Acid Supply/Demand and Trade ...................................... 13-115
13.81 Asia Pacific Acrylic Acid Consumption by Country.............................................. 13-117
13.82 Asia Pacific Acrylic Acid Consumption................................................................. 13-117
13.83 Acrylic Acid Capacity in Asia Pacific .................................................................... 13-119
13.84 Asia Pacific Acrylic Acid Supply/Demand and Trade ........................................... 13-120
13.85 U.S. Acetylene Producers (Chemical Use), end 2006 ............................................ 13-121
13.86 West European Acetylene Producers (Chemical Use), End 2006 .......................... 13-121
13.87 Japanese Acetylene Producers (Chemical Use), 2006............................................ 13-122
13.88 Chinese Acetylene Producers (Chemical Use), 2006 ............................................. 13-123