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1996 Bookmatter AnIntroductionToIndustrialChem
1996 Bookmatter AnIntroductionToIndustrialChem
Industrial Chemistry
This book is dedicated to
the memory of my Father,
John Arthur Alan Heaton
An Introduction to
Industrial Chemistry
Third edition
Edited by
Alan Heaton
Reader in Industrial Chemistry
School of Pharmacy and Chemistry
Liverpool John Moores University
Following the success of the first two editions of this book in which the core
subject matter has been retained, we have taken the opportunity to add
substantial new material, including an additional chapter on that most
important activity of the chemical industry, research and development.
Topical items such as quality, safety and environmental issues also receive
enhanced coverage.
The team of authors for this edition comprises both those revising and
updating their chapters and some new ones. The latter's different approach to
the subject matter is reflected in the new titles: Organisational Structures - A
Story of Evolution (chapter 5) and Environmental Impact of the Chemical
Industry (chapter 9). The chapter on Energy retains its original title but
different approach of the new authors is evident.
We have updated statistics and tables wherever possible and expanded the
index. We hope readers find the brief 'pen pictures' of authors to be
interesting.
It is worth stressing again that this book is designed to be used with its
companion volume - The Chemical Industry, 2nd Edition, ed. Alan Heaton
(referred to as Volume 2) - for a complete introduction to the chemical
industry.
Thanks are due to all contributors and to my wife Joy for typing my
contributions.
Alan Heaton
Contents
Editorial introduction 1
Alan Heaton
The importance of industrial chemistry 1
Statistics 3
Units and nomenclature 4
General bibliography 5
References 6
1 Introduction 7
Alan Heaton
1.1 Characteristics of the industry 8
1.2 Scale of operations 9
1.3 Major chemical producing countries 10
1.4 Major sectors and their products 10
1.5 Turning chemicals into useful end products 12
1.6 Environmental issues 13
1.6.1 Flixborough 13
1.6.2 Minamata Bay (Japan) 14
1.6.3 Thalidomide and drugs 14
1.6.4 Seveso, Bhopal and pesticides 15
1.6.5 Hickson and Weich, Castleford 15
1.6.6 CFCs (chlorofluorocarbons) 16
1.7 Quality and safety 17
1. 7.1 Quality 17
1. 7.2 Safety 17
2 Sources of chemicals 19
Alan Heaton
2.1 Introduction 19
2.2 Sources of organic chemicals 24
2.2.1 Organic chemicals from oil and natural gas 25
2.2.2 Organic chemicals from coal 29
2.2.3 Organic chemicals from carbohydrates (biomass) 37
2.2.4 Organic chemicals from animal and vegetable oils and fats 40
2.3 Sources of inorganic chemicals 42
2.4 Recycling of materials 43
References 44
Bibliography 44
8 Energy 232
Will Bland and Ted Laird
8.1 Introduction 232
8.1.1 Energy required by the chemical industry 232
8.1.2 Sources of energy 233
8.1.3 Cost of energy 235
8.1.4 Environmental factors 236
8.1.5 Properties of fuels 237
8.2 Types of energy 238
8.2.1 Variation in energy content requirement 240
8.3 Use of energy in the chemical industry 240
8.3.1 Batch reactors 240
8.3.2 Continuous reactors 241
8.3.3 Electrochemical reactors 242
8.3.4 Preparation and separation energy 242
8.3.5 Heat transfer media 243
8.4 Efficient utilization of energy 245
8.4.1 Exothermic reactions 245
8.4.2 Separation processes 246
8.4.3 Restriction of losses 247
8.5 Conclusions 248
Appendix 249
References 249
Bibliography 250
12 Petrochemicals 350
John Pennington
12.1 Introduction 350
12.1.1 Layout 350
12.1.2 The beginnings 350
12.1.3 Into the 1970s 351
12.1.4 The present 351
12.1.5 Individual feedstocks and routes 352
12.2 Crude oil, gas and refinery operations 353
12.2.1 Crude oil and natural gas 353
12.2.2 Refinery operations 353
12.2.3 Energy consumption 355
12.3 Lower olefins (alkenes) and acetylene (ethyne) 356
12.3.1 Cracking processes 356
12.3.2 Energy balances and economics 359
12.3.3 Lower olefins (alkenes) versus acetylene (ethyne) 364
12.3.4 Polyethylene (polyethene) and polypropylene (polypropene) 366
12.3.5 Production and use statistics 366
12.4 Synthesis gas, ammonia and methanol 368
12.4.1 Process descriptions 368
12.4.2 Energy balances and economics 371
12.4.3 Urea (carbamide), formaldehyde (methanal), amino resins
and polyacetal 373
12.4.4 Production and use statistics 374
12.5 Acetic (ethanoic) acid and anhydride 374
12.5.1 Acetic acid production 374
12.5.2 Acetic anhydride production 377
12.5.3 Production and use statistics 377
12.6 C 1 products 378
12.6.1 Formic (methanoic) acid and derivatives 378
12.6.2 Hydrogen cyanide 379
12.6.3 Chloromethanes 379
12.7 C 2 products 379
12.7.1 Ethanol 379
12.7.2 Acetaldehyde (ethanal) 380
12.7.3 Ethylene oxide (oxirane) and glycol (ethane-l,2-diol) 381
12.7.4 Vinyl acetate (ethenyl ethanoate) 381
12.7.5 Choroethylenes (chloroethenes) and chloroethanes 382
12.8 C 3 products 383
12.8.1 Isopropanol (2-propanol) and acetone (propanone) 383
12.8.2 Propylene oxide (l-methyloxirane) and glycol (propane-l,2-
diol) 383
12.8.3 Acrylonitrile (propenonitrile) 384
12.8.4 Acrylates and acrolein (propenal) 384
12.8.5 Allylic (propenyl) derivatives 385
12.8.6 n-Propanol, propionaldehyde (propanal) and propionic
(propanoic) acid 385
CONTENTS xiii
Index 403
Contributors
Dr. Derek Bew Formerly of I CI Petrochemicals & Plastics Division, Wilton
Derek Bew obtained his M.Sc. in 1951 and Ph.D. in Organic Chemistry in 1954. He then joined
ICI's Billingham Division and spent periods in Research and Market Development, Process
Development and Plant Management and then in Project Management in the Technical
Department. There followed an extended period in the Research and Technology Department
working on Process Economics and Evaluation. Derek retired from ICI in 1990.
Dr. Will Bland Department of Chemistry and Applied Chemistry, Kingston University, Penrhyn
Road, Kingston-upon-Thames, Surrey KT2IIEE
Will Bland worked for three years as a research chemist in industry, obtained his B.Sc. and Ph.D.
from the University of Leicester and is currently Acting Associate Head of the School of Applied
Chemistry at Kingston University as well as being Course Director of the B.Sc. (Honours) Degree
in Environmental Science. His main teaching and research interests are in Industrial Chemistry,
Resources and the Environment. He is a Fellow of the Royal Society of Chemistry and a member
of the Committee of Tertiary Education Group.
Dr. Alan Heaton School of Pharmacy and Chemistry, Liverpool John Moores University, Byrom
Street, Liverpool L4 3AF
Alan Heaton worked in the coal-tar chemicals industry as a young man whilst studying for the
Grad. R.I.C. qualification. He obtained his Ph.D. in Organofluorine Chemistry at Durham
University in 1967. Following a brief spell as Lecturer in Organic Chemistry at the University of
Salford, he joined Liverpool Polytechnic in 1969, where he was given responsibility for
developing courses in the area oflndustrial Chemistry. He is now Reader in Industrial Chemistry
at Liverpool John Moores University and carries out research in the areas of organofluorine
chemistry and pesticides.
Since 1971 he has been a Tutor, Tutor Counsellor and Consultant to the Open University. He
is a nationally-elected member of the Council of the Royal Society of Chemistry and serves on the
Awards Committee of the Society of Chemical Industry as well as being on a number of
committees of each of these societies at regional and 10calleve1s.
Dr. Andrew S. Hursthouse Department of Chemistry and Chemical Engineering, University of
Paisley, High Street, Paisley P Al 2BE
Andrew Hursthouse is a geochemist and a senior lecturer in the Department of Chemistry and
Chemical Engineering, University of Paisley. His research interests cover: environmental
analysis, the mobility of inorganic and organic species in the environment, the biogeochemistry of
metallic and organic compounds and the environmental impact of waste discharges. He has acted
as a consultant for industrial and public bodies on a range of environmental problems and
manages the Centre for Particle Characterisation and Analysis and R&D, problem solving
facility for industry within the Faculty of Science and Technology.
Mr. Steve Kelham Process Development Group, Research and Technology Department, ICI
Chemicals and Polymers, PO Box 8, The Heath, Runcorn WA74QD
Steve Kelham has had over 20 years of experience of the Chlor-Alkali Industry. He graduated
from Cambridge University in 1968 and joined ICI as a Chemical Engineer. He has been
primarily involved in process design, plant troubleshooting, commissioning and business
development activities linked to chI or-alkali production from mercury, diaphragm and
membrane cells at plants around the world. Currently he is managing process development
activities within the R&T area in ICI at Runcorn, Cheshire.
Mr. Ted Laird Department of Chemistry and Applied Chemistry, Kingston University, Penrhyn
Road, Kingston-upon- Thames, Surrey KT2I 1EE
Ted Laird took his B.Sc. chemistry degree plus his Ph.D. in physical-organic chemistry at
Southampton University. After 2 years in the RAF he joined ICI to work in a physical chemistry
laboratory. He worked on plant problems at their Wilton Works and then moved on to BNFL to
carry out similar work.
He became a chartered chemical engineer and has taught mainly industrial chemistry at
Kingston Polytechnic and University for the last 27 years before recently retiring.
xvi CONTRIBUTORS
Mrs. Jo McCloskey Business School, Liverpool John Moores University, 98 Mount Pleasant,
Liverpool L3 5UZ
Jo McCloskey has studied at universities in Ireland and Scotland. She worked in the public sector
before embarking on an academic career. She taught in Ireland and Africa before coming to
England. She came to Liverpool Business School after having taught at Leicester Business
School. Currently, she is Principal Lecturer and Head of Business Policy and Marketing.
Her research interests and recent publications have been in the areas of environmental
management and marketing. She is an experienced marketing and management consultant,
having completed various projects in Europe, U.S.A. and Africa.
Mr. John Pennington 4 Bessacarr Avenue, Willerby, Hull HUlO 6JA
After graduation and a spell in research at Cambridge University, John Pennington joined the
Research and Development laboratories attached to a manufacturing site for bulk organic
chemicals near Hull, now owned by BP Chemicals. The work primarily involved factory support
and new process development, in both laboratory and pilot plant, but occasionally more
speculative research. John progressed in a technical capacity, latterly as a company-wide 'internal
consultant' until (early) retirement (at the end of 1988).
Dr. Richard Szczepanski lnfochem Computer Services Ltd., South Bank Technopark, 90 London
Road, London SEI 6LN
Richard Szczepanski is a director of Infochem Computer Services Ltd., a consultancy specializing
in physical property data and software for chemical engineering and petroleum engineering
applications. His main area of work is in modelling phase and chemical equilibria. Dr.
Szczepanski was formerly a Project Leader at the BP Research Centre and a lecturer in chemical
engineering at Imperial College, London.
Conversion factors
H, ~
c-c
Maleic anhydride cis-Butenedioic anhydride II
c-c'
'0
H/ II
o
NOMENCLATURE OF ORGANIC COMPOUNDS XXI
CH 2C0 2 H
I
Citric acid 2-Hydroxypropane-l, 2, 3- HO-C-C0 2 H
tricarboxylic acid I
CH 2C0 2 H
Methyl laurate Methyl dodecanoate CH3(CH2)10C02CH3
Stearic acid Octadecanoic acid CH3(CH2)16C02H
Acrylonitrile Propenonitrile CH 2 =CH-CN
Adiponitrile Hexane-I,6-dinitrile NC-(CH 2)6-CN
Urea Carbamide H 2 NCONH 2
Ketene Ethenone CH 2 =C=O
Toluene Methylbenzene
6
Aniline Phenylamine
8
C~l/CH]
6
CH
(reH]
a-Xylene i,2-Dimethylbenzene
m-Xylene i,3-Dimethylbenzene
&
"" CH 1
p-Xylene i,4-Dimethylbenzene
QCH]
C0 2 H
Phthalic acid Benzene-i,2-dicarboxylic H
( r e 02
acid
(YCHJ
C0 2 H
CHO
p- Tolualdehyde 4-Methylbenzaldehyde
¢cAl
Furfural 2-Formylfuran
CrCHO