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Global ethylene production was 190 million tonnes and propylene was 120 million tonnes in 2019. [4] Aromatics production is approximately 70 million tonnes. The largest petrochemical industries are located in the USA and Western Europe; however, major growth in new production capacity is in the Middle East and Asia. There is substantial inter-regional petrochemical trade.
Primary petrochemicals are divided into three groups depending on their chemical structure:
Aromatics includes benzene, toluene and xylenes, as a whole referred to as BTX and primarily obtained from petroleum refineries by extraction from the reformate produced in catalytic reformers using naphtha obtained from petroleum refineries. Alternatively, BTX can be produced by aromatization of alkanes.[5][6][7] Benzene is a raw material for dyes and synthetic detergents, and benzene and toluene for isocyanatesMDI and TDI used in making polyurethanes. Manufacturers use xylenes to produce plastics and synthetic fibers.
In 2007, the amounts of ethylene and propylene produced in steam crackers were about 115 Mt (megatonnes) and 70 Mt, respectively.[8] The output ethylene capacity of large steam crackers ranged up to as much as 1.0 - 1.5 Mt per year.[9]
The adjacent diagram schematically depicts the major hydrocarbon sources and processes used in producing petrochemicals.[2][3][10][11]
Petrochemical feedstock sources
Like commodity chemicals, petrochemicals are made on a very large scale. Petrochemical manufacturing units differ from commodity chemical plants in that they often produce a number of related products. Compare this with specialty chemical and fine chemical manufacture where products are made in discrete batch processes.
Petrochemicals are predominantly made in a few manufacturing locations around the world, for example in Jubail & Yanbu Industrial Cities in Saudi Arabia, Texas & Louisiana in the US, in Teesside in the Northeast of England in the United Kingdom, in Rotterdam in the Netherlands, in Jamnagar, Dahej in Gujarat, India and in Singapore. Not all of the petrochemical or commodity chemical materials produced by the chemical industry are made in one single location but groups of related materials are often made in adjacent manufacturing plants to induce industrial symbiosis as well as material and utility efficiency and other economies of scale. This is known in chemical engineering terminology as integrated manufacturing. Specialty and fine chemical companies are sometimes found in similar manufacturing locations as petrochemicals but, in most cases, they do not need the same level of large-scale infrastructure (e.g., pipelines, storage, ports, and power, etc.) and therefore can be found in multi-sector business parks.
The large scale petrochemical manufacturing locations have clusters of manufacturing units that share utilities and large scale infrastructures such as power stations, storage tanks, port facilities, road and rail terminals. In the United Kingdom, for example, there are 4 main locations for such manufacturing: near the River Mersey in North West England, on the Humber on the East coast of Yorkshire, in Grangemouth near the Firth of Forth in Scotland, and in Teesside as part of the Northeast of England Process Industry Cluster (NEPIC). To demonstrate the clustering and integration, some 50% of the United Kingdom's petrochemical and commodity chemicals are produced by the NEPIC industry cluster companies in Teesside.
synthetic rubbers - synthetic elastomers made of any one or more of several petrochemical (usually) monomers such as 1,3-butadiene, styrene, isobutylene, isoprene, chloroprene; elastomeric polymers are often made with a high percentage of conjugated diene monomers such as 1,3-butadiene, isoprene, or chloroprene
higher olefins
polyolefins - such poly-alpha-olefins, which are used as lubricants
alpha-olefins - used as monomers, co-monomers, and other chemical precursors. For example, a small amount of 1-hexene can be copolymerized with ethylene into a more flexible form of polyethylene.
phenol - hydroxybenzene; often made by the cumene process
acetone - dimethyl ketone; also often made by the cumene process
bisphenol A - a type of "double" phenol used in polymerization in epoxy resins and making a common type of polycarbonate
epoxy resins - a type of polymerizing glue from bisphenol A, epichlorohydrin, and some amine
polycarbonate - a plastic polymer made from bisphenol A and phosgene (carbonyl dichloride)
solvents - liquids used for dissolving materials; examples often made from petrochemicals include ethanol, isopropyl alcohol, acetone, benzene, toluene, xylenes
cyclohexane - a 6-carbon aliphatic cyclic hydrocarbon sometimes used as a non-polar solvent
adipic acid - a 6-carbon dicarboxylic acid, which can be a precursor used as a co-monomer together with a diamine to form an alternating copolymer form of nylon.
nylons - types of polyamides, some are alternating copolymers formed from copolymerizing dicarboxylic acid or derivatives with diamines
polyesters - although there can be many types, polyethylene terephthalate is made from petrochemical products and is very widely used in petrol stations
^Hassan E. Alfadala, G.V. Rex Reklaitis and Mahmoud M. El-Halwagi (Editors) (2009). Proceedings of the 1st Annual Gas Processing Symposium, Volume 1: January, 2009 - Qatar (1st ed.). Elsevier Science. pp. 402-414. ISBN978-0-444-53292-3.CS1 maint: extra text: authors list (link)