Topic 3.1 Chemical Industry

Chemical Industry Overview

• The chemical industry is integral to societal and economic growth.
• It plays a crucial role in providing essential products like food, shelter, and clothing.

Top Ten Chemical Companies

• The chemical industry has recovered from the COVID-19 pandemic and is experiencing growth fueled by higher prices.

Organic and Inorganic Chemicals

• Chemicals are classified as either organic or inorganic.
• Organic chemistry encompasses carbon-containing compounds.
• Inorganic chemistry focuses on elements from the periodic table and their compounds.
• Petrochemicals are a significant sub-section of organic chemistry.

Organic Chemicals

• William Henry Perkin was the first chemist to synthesize a commercial organic chemical, mauveine dye, in 1856.
• The development of synthetic dyes and other synthetic organic chemicals stimulated demand for aromatics derived primarily from coal tar.
• Examples of organic chemicals include hydrocarbons, oxygen- and hydroxy-containing compounds, nitrogen compounds, sulfur compounds, phosphorus compounds, and organometallic compounds.

Inorganic Chemicals

• Important early industrial chemicals were sulfuric acid and sodium carbonate.
• The lead chamber process, developed by John Roebuck in 1746, revolutionized sulfuric acid production. Sulfuric acid is still the most produced chemical.
• The Leblanc process, invented by Nicholas Leblanc, provided a cost-effective method for producing sodium carbonate, significantly impacting the modern chemical industry.
• Examples of inorganic chemicals include acids, bases, metals, salts, and minerals.

The Oil Era

• The use of crude oil and natural gas as raw materials for organic chemical production began in the 1930s in the United States.
• The petrochemical industry expanded during World War II due to the need for aromatics in aviation fuel.
• The rise of the automobile increased demand for gasoline and diesel, which remain major refinery products.
• Catalytic cracking, developed by Houdry in 1936, significantly improved gasoline yields.
• Environmental concerns in the 1960s and 70s led to the development of environmental catalysis, exemplified by catalytic cleaning of car exhaust gases.
• Steam reforming of natural gas is a key process in chemical plants, using natural gas as both feedstock and fuel.
• Electricity can be generated on-site in steam turbines or purchased from local suppliers.
• Large-scale operations can benefit from on-site electricity generation to reduce energy costs.

Base Chemicals

• A limited number of base chemicals are used as building blocks for the vast majority of chemical products.
• Important organic base chemicals include alkenes (ethene, propene, butadiene), aromatics (benzene, toluene, xylene), and methanol.
• Synthesis gas (hydrogen and carbon monoxide mixture) is also a key organic base chemical.
• Sulfuric acid and ammonia are the two most important inorganic base chemicals.

Chemical Production & Energy Carriers

• Base chemicals account for a significant portion of chemical production but are less than the combined production of gasoline and diesel, highlighting the massive consumption of fuels.

Production Sources

• Light alkenes are mainly produced from crude oil via steam cracking of ethane, propane, and butane, particularly in the USA and the Middle East. Steam cracking of naphtha is also a significant source in other parts of the world.
• Light alkene production from natural gas is prominent in the USA and the Middle East.
• Aromatics are produced from pyrolysis gasoline (pygas), while chemicals derived from synthesis gas are also important.