Escolar Documentos
Profissional Documentos
Cultura Documentos
Non-polymer Derivatives
of Propylene
Rajeev M Pandia
March 2014
Contents
Propylene Sources and Technologies
Overall Global and Asian Scenarios of Propylene and its Derivatives
Demand-Supply, Technologies, New Projects
Acetone/ Phenol
Acrolein/ Acrylic Acid/ Acrylonitrile
Propylene Oxide
Oxo-alcohols
Iso-propanol
Conclusions
2
Steam
Cracking
Gas Oil
Refinery FCC
Unit
RG Propylene
Propane
PDH
Ethylene/
Butenes
Metathesis
Methanol
or Coal
MTO / MTP
CTO
Gas Oil
High Severity
FCC
C4 to C8
Olefins
Olefins
Cracking
Source: Intratec
CG/PG
Propylene
Propylene Technologies
Technologies
Conventional
Technologies
Conventional steam
cracking
Off gases from Fluid
Catalytic Cracking
(FCC) units in
refineries
Catalytic cracking:
Selective Olefin
Cracking, Deep
Catalytic Cracking
Enhanced (High
Severity) FCC
On-Purpose
Technologies
Bio-Propylene
Propane
Dehydrogenation
Metathesis
Methanol to Olefins /
Methanol to
Propylene
Coal to Olefins
Corn, Sugar or
Switchgrass
Fermentation
(Ethanol based)
Fermentation to
Propanol (Corn or
Sugar based)
Biomass Gasification
PP
Oxo-Alcohols
Propylene
Oxide
2-Ethyl
Hexanol
Propylene
Glycol
Acrylic
Fiber
Butanol
Polyols
ABS
SAN
NBR
ACN
Cumene
Phenol
and
Acetone
Acrylic
Esters
Acrylic
Acid
Acrolein
Methionine
IPA
Alkylates
Dimersol
Polymer Gasoline
Propylene Oligomers
Iso-Butyl Benzene
EPDM Rubbers
BPA
MMA
PROPYLENE : Highlights
Source: CHEMSYSTEMS-Nexant
Acrylonitrile
7%
Polypropylene
63%
Acrylic
Acid
Isopropanol 4%
2%
Propylene
Oxide
7%
Others
(Oligomers
and
Rest)
11%
Source: Chemsystems (Nexant)
SOUTH AFRICA
AMERICA 2%
4%
MIDDLE EAST
9%
ASIA
43%
EUROPE
20%
NORTH
AMERICA
22%
Source: ICIS
PROPYLENE-ASIA-CAPACITY DISTRIBUTION
TOTAL: 43.7 MN TPA
INDONESIA
2%
MALAYSIA
3%
THAILAND
5%
INDIA
5%
SINGAPORE
6%
PHILLIPINES
<1%
VIETNAM
<1%
CHINA
34%
AUSTRALIA
7%
TAIWAN
9%
Source: ICIS
JAPAN
14%
SOUTH KOREA
15%
10
11
Phenol Chain
Phenolic Resins
Phenol
Nylon Intermediates
Benzene
Epoxy Resins
Cumene
Bisphenol A
Polycarbonates
Propylene
Acetone
MMA
Solvents
12
AFRICA
<1%
MIDDLE
EAST
2%
NORTH
AMERICA
25%
EUROPE
27%
ASIA
44%
THAILAND
4%
INDIA
1%
SINGAPORE
6%
JAPAN
17%
SOUTH
KOREA
19%
CHINA
32%
TAIWAN
21%
Source: ICIS
13
Alkyl
Phenols
4%
Others
14%
Caprolactam
8%
Bisphenol
49%
Phenolic
Resins
25%
Source: ICIS
14
Source: IHS
15
SOUTH
AFRICA
2%
SOUTH MIDDLE
AMERICA EAST
2%
2%
NORTH
AMERICA
24%
ASIA
43%
ACETONE-ASIA CAPACITY
DISTRIBUTION
TOTAL: 3.17 MN TPA
EUROPE
27%
THAILAND
4%
SINGAPORE
6%
JAPAN
18%
SOUTH
KOREA
19%
Source: ICIS
INDIA
1%
CHINA
31%
TAIWAN
21%
16
2000
1800
1600
1400
1200
1000
800
600
400
200
PROPYLENE-USA-EXPORT
Nov-13
Sep-13
Jul-13
May-13
Mar-13
Jan-13
Nov-12
Sep-12
Jul-12
May-12
Mar-12
Jan-12
Nov-11
Sep-11
Jul-11
May-11
Mar-11
Jan-11
Nov-10
Sep-10
Jul-10
May-10
Mar-10
Jan-10
PHENOL-USA-EXPORTS
ACETONE-USA-EXPORTS
SOURCE: USITC, ICIS
17
18
Acrylic Acid
Glacial
Acrylic
Acid
Segmentwise
Application
Detergent
cobuilders
10%
Water
treatment
16%
Superabsor
bent
polymers
(SAPs)
74%
Source: IHS
Glacial Acrylic Acid (GAA) is the largest outlet for crude acrylic acid.
20
NORTH
AMERICA
21%
EUROPE
22%
ASIA
53%
Capacity,
TPA
Completed by
Tasnee/Sahara
Petrochemical
250,000
2013
Rabigh Refining
& Petrochemical
Co (PetroRabigh)
100,000
2016
INDONESIA
4%
MALAYSIA
5%
TAIWAN
5%
SOUTH
KOREA
11%
CHINA
52%
JAPAN
20%
Source: ICIS
Company
Kuwait Petroleum/Sinopec
Capacity,
TPA
Region
Location
Guangdong
Zhangjiang,
Guangdong
150,000
Sichuan
Pengzhou
190,000
Anhui
Wuwei, Anhui
400,000
Jiangsu
Nantong.
Jiangsu
80,000
Source: ICIS
23
Japan Catalytic
Chemical Co.
Japan
Mitsubishi
Petrochemical Co,
Japan
Toyo Soda
Company, Japan
Sumitomo
Chemical Co.,
Japan
Nippon Shokubai
Kagaku Kogyo Co.
Ltd., Japan
SOHIO, U.S.A.
BASF, Germany
Celanese
Corporation, U.S.A.
24
ACRYLONITRILE
25
ACRYLONITRILE : Highlights
Manufactured by ammoxidation of Propylene
Sohio developed the process
Initial demand driver : Acrylic Fibre ( DuPont)
Propane based competitive process ( BP, Mitsubishi, Asahi
Kasei)
26
Acrylic Fibre
Sweaters,
Blankets,
Scarves, Hats,
Rugs, Hand
Knitting Yarn,
Toys, Wigs,
Furnishings,
etc.
ABS/SAN
TVs, Phones,
Computers,
Other
Electronics,
Cars/Vehicles,
Home
Appliances,
Toys, Medical,
etc.
Acrylonitrile has
numerous end uses
NB Copolymers
Polyacrylamide
Construction,
Automobile
Parts, Cables,
Rubber Gloves,
Hoses,
Conveyor
Belts, etc.
Water
Treatment, Oil
Industry, Pulp
and Paper,
Minerals/
Mining,
Enhanced Oil
Recovery,
Shale Gas etc.
Carbon Fibre
Aircraft,
Military, Racing
Cars,
Passenger
Cars, Wind
Turbines, Golf
Clubs etc.
27
Acrylonitrile Capacities
ACRYLONITRILE - GLOBAL
CAPACITY DISTRIBUTION
TOTAL: 7.04 MN TPA
SOUTH
AMERICA
2%
AFRICA
1%
THAILAND INDIA
1%
5%
EUROPE
20%
NORTH
AMERICA
22%
TAIWAN
14%
ASIA
55%
CHINA
37%
JAPAN
21%
SOUTH
KOREA
22%
Source: ICIS
28
Acrylonitrile Demand
Segmentwise Distribution of Global
Demand for ACN Total 4.762 mn
TPA
ABS/SAN,
1.70, 36%
Adiponitrile
, 0.33, 7%
Acrylamide,
0.43, 9%
Acrylic
Fiber, 1.84,
38%
NB
Copolymers
, 0.23, 5%
Others,
0.23, 5%
Source: IHS
29
Company
Asahi Kasei Corp/ SABIC
China Petrochemical
Development Corp - (CPDC)
Mehr Petro Kimia Co (Mepekco)
SINOPEC-Wanda Group JV
Country
Capacity, TPA
Status
Saudi Arabia
200,000
study (prefeasibility)
Taiwan
50,000
planned
Iran
90,000
planned
China
260,000
construction
underwayEXPECTED
COMMNG-OCT
2014
Source: ICIS
30
Acrylonitrile-Butadiene-Styrene (ABS)
ABS- GLOBAL CAPACITY
DISTRIBUTION
SOUTH
AMERICA
1%
MIDDLE
EAST
1%
OTHERS
7%
INDIA
2%
JAPAN
8%
EUROPE
10%
CHINA
45%
SOUTH
KOREA
19%
TAIWAN
19%
ASIA
80%
Source: ICIS
3000
2500
2000
1500
1000
500
PROPYLENE-USA-EXPORT
11-13
9-13
7-13
5-13
3-13
1-13
11-12
9-12
7-12
5-12
3-12
1-12
11-11
9-11
7-11
5-11
3-11
1-11
11-10
9-10
7-10
5-10
3-10
1-10
ACN-USA-EXPORTS
32
PROPYLENE OXIDE
33
Propylene Glycol (PG) is used as solvent and for UPRs, HTFs, anti-freeze,
aircraft, deicing fluids etc.: Growing at a CAGR of 2-3% globally
PG ethers are used as solvent in coatings, inks etc.
USA is the largest consumer for PG, with about 1/3rd of the world total.
PO
Application
wise
Demand
Distribution
Propylene
Glycol
18%
Polyether
Polyols
66%
Glycol
Ethers
5%
Others
(Butanediol,
Mod.
Starch,
Synthetic
Lubes)
11%
34
PO Technologies
Dow Hydrogen
Peroxide based
Process
The H2O2 process
Developed and put
to use jointly by
BASF and Dow in
Antwerp,
SCG-Dow Group, a
JV between Dow
and Siam Cement
Group in Thailand)
Chlorohydrin
Process
Propylene Oxide /
Styrene Co-product
Process (PO/SM)
Propylene Oxide /
Styrene Co-product
Process (PO/SM)
Sumitomo PO only
Cumene-based
Process
This process was
commercialized by
Sumitomo
PO/TBA
16%
CHP
(Sumitomo)
4%
HPPO
5%
CHPO
43%
Source: Chemsystems
35
MIDDLE
EAST
2%
INDIA
1%
THAILAN
D
10%
NORTH
AMERICA
25%
SOUTH
KOREA
8%
ASIA
40%
SINGAPO
RE
11%
EUROPE
31%
CHINA
56%
JAPAN
14%
Source: ICIS
36
Country
Capacity,
TPA
BASF-YPC Co Ltd
China
Changling Petrochemical Co
China
China
China
China
250000
China
300000
China
150000
Expected
in
Status
study (pre-feasibility)
100000
2013
construction underway
study
2016
study
2015
construction underway
construction underway
2016
study
2016
planned
Petronas/Evonik
Malaysia
Sadara Chemical
Saudi Arabia
approved
Saudi Arabia
study
China
engineering underway
37
SOUTH
AMERICA
4%
SINGAPORE
6%
ASIA
37%
EUROPE
29%
AUSTRALIA
2%
SOUTH
KOREA
10%
THAILAND
15%
NORTH
AMERICA
30%
INDIA
1%
CHINA
49%
JAPAN
17%
38
Country
Capacity
Australia
15,000
China
60,000
India
15,000
Japan
33,000
Japan
42,000
Japan
100,000
Singapore
65,000
S. Korea
100,000
SCG-Dow Group
Thailand
150,000
39
Price Trends
40
OXO ALCOHOLS
41
42
2-Ethyl Hexanol
Source: Researchpub
Applications
2-ethylhexyl phthalate plasticizers for flexible PVC
For the production of intermediates for acrylic
surface coatings, diesel fuel, and lube oil additives
End markets: Building and construction,
transportation, medical, consumables, and durable
goods manufacture
43
Country
Capacity
Status
MTPA
China
China
India
140,000 study
China
80,000 study
China
China
China
China
125,000 study
Xingxia Petrochina
China
1,195,000
Source: ICIS
44
n-Butanol
Applications
45
Company
China
115000
planned
China
210000
study
Saudi
Arabia
330000
study
China
206000
planned
China
85000
engineering
underway
China
125000
study
1,481,000
Source: ICIS
46
i-Butanol
Producers
BASF, Perstorp, Dow, Oxea, Formosa, LG, Eastman, Hanwha, Andhra
Petchem, Oxochimie, Sasol, Tianjin Bohai Chemical Group, Asahi
Kasei, Zaklady
Applications
To manufacture Plasticizers, Amino Resin, Isobutyl Acetate and
Solvents
Company
Country Status
Gevo
Malaysia
Gevo
US
study
planned
China
study
China
planned
China
study
47
4.00
3.50
3.57
3.30
2.94
Million tons
3.00
2.94
2.87
2.87
2.50
2.00
1.50
1.00
0.50
-
n-Butanol
2-Ethylhexanol
Capacity
Production
Demand
OXO Supply and Demand in China during 2008-2015 (in 000 tons per year)
Name
N-Butanol
2-Ethyl
hexanol
Item
2008
2009
2010
2015
Capacity
365
365
550
1185
Demand
632
890
850
1100-1150
Capacity
540
540
875
1375
Demand
829
940
900
1200-1300
48
ISO-PROPYL ALCOHOL
49
South
America,
58,000
,
2%
Europe,
580,000
,
21%
Asia,
1,130,000
,
42%
IPA Projects
Company
Country
Region
Capacity
Capacity
Type
Chang Chun
Plastics Co Ltd
China
Panjin, Liaoning
80000
Total
Novapex
France
Roussillon
20000
Expansion
Source: ICIS
Completed
by
2013/14
2013/ 14
50
China Plants
Company
Source: ICIS
Location
Capacity
Liaoning
Jinzhou
100000
Shandong
Dezhou
50000
Shandong
Dongying
50000
Zhejiang
Jiande
100000
Jiangsu
Yancheng
50000
Jiangsu
Yancheng
50000
Taixing Jianye
Jiangsu
Taixing
30000
Region
51
1700
1600
1500
1400
1300
1200
1100
PROPYLENE-USA-EXPORT
11-13
9-13
7-13
5-13
3-13
1-13
11-12
9-12
7-12
5-12
3-12
1-12
11-11
9-11
7-11
5-11
3-11
1-11
11-10
9-10
7-10
5-10
3-10
1-10
1000
IPA-USA-EXPORT
52
Conclusions
Propylene to show reasonably good growth in future
Asia to lead future growth with better growth prospects in
most of the derivatives, mainly in China