Production
Ethylene and propylene are primarily produced through the cracking of hydrocarbons. Cracking involves breaking the chemical bonds within larger hydrocarbon molecules and rearranging them into smaller molecules. The two most common cracking processes used are steam cracking and fluidized catalytic cracking.
Steam cracking, also called thermal cracking, involves heating petroleum feedstocks such as naphtha, gas oil or liquefied petroleum gas in the presence of steam in furnaces at 800-900°C under atmospheric pressure. This causes the hydrocarbon molecules to break into smaller olefin molecules like ethylene and propylene.
Fluidized catalytic cracking (FCC) uses a fine powder catalyst, usually zeolite, suspended in hot gas to promote cracking reactions. In FCC units, heavier feedstocks like vacuum gas oil are vaporized and introduced into the riser reactor where they contact the hot catalyst. Cracking reactions convert the large hydrocarbon molecules into lighter, more valuable products including olefins. FCC is a major source of propylene production.
Uses of Ethylene
Due to its versatility, Ethylene and Propylene is used to produce a wide range of derivatives that are essential to our daily lives. Some key end uses of ethylene are:
- Polyethylene - Ethylene is polymerized to form polyethylene, which is the most widely used plastic in the world. Applications include plastic bags, containers, pipes and films.
- Ethylene glycol - Produced by hydrating ethylene oxide, ethylene glycol is primarily used to make polyester fibers and plastic containers. It is also a major component in antifreeze.
- Ethyl benzene - Condensed with benzene, ethyl benzene is the precursor to styrene monomer used to manufacture polystyrene plastics and synthetic rubbers.
- Ethylene dichloride - Formed by chlorinating ethylene with chlorine gas, ethylene dichloride is used to manufacture polyvinyl chloride (PVC) resins for pipes, siding and other building materials.
Uses of Propylene
Propylene has nearly as many applications as ethylene due to the variety of chemicals derived from it:
- Polypropylene - Polymerized propylene is used extensively in packaging films, molded containers and automobile components. It has gained popularity as a replacement for polyethylene and PVC.
- Propylene oxide - Formed by oxidizing propylene, propylene oxide is hydrated to make polyether polyols for polyurethane foams and adhesives.
- Cumene - Formed from the alkylation of benzene with propylene, cumene is oxidized to produce phenol and acetone. Phenol is used to make epoxy, polycarbonate and nylon resins.
- Acrylonitrile - A building block for acrylic fibers, ABS resins and nitrile rubbers. It is formed by ammoxidation of propylene.
- Propylene glycol - Hydrated propylene oxide is an important component of polyester resins and unsaturated polyester resins. It is also found in antifreeze, food and personal care products.
Economics and Growth
Ethylene and propylene are critical feedstocks for the petrochemical industry. Worldwide ethylene capacity was nearly 200 million tons in 2020 and is projected to grow to nearly 250 million tons by 2030. Global propylene capacity in 2020 was around 90 million tons with growth projections of 10-15% by 2030.
Asia Pacific is the largest and fastest growing for olefins due to new construction of refineries and steam crackers. Countries like China, India, South Korea and Indonesia will account for a major share of the increase in global ethylene and propylene capacity over the next decade. North America and Europe are also expanding capacity with more ethane from shale production. With growth in derivative s, the olefins industry will continue to grow substantially, fueled by increases in supply to meet polymer demand.
Advancements like low-energy steam crackers using new catalysts offer greater profitability and reduced emissions. Integration of production also allows better utilization of by-products. As technologies progress, the petrochemical industry will remain a major driver of economic growth globally through the widespread use of plastics, fibers and countless everyday products derived from ethylene and propylene.
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About Author:
Money Singh is a seasoned content writer with over four years of experience in the market research sector. Her expertise spans various industries, including food and beverages, biotechnology, chemical and materials, defense and aerospace, consumer goods, etc. (https://www.linkedin.com/in/money-singh-590844163)
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