CLASSIFICATION OF PETROCHEMICALS
The nature of petrochemical industry is very complex. The journey from petroleum to
useful end products is long and there are many steps in the process.
Feed Stock
The starting material used for the production of petrochemicals is called feed stock. There are
two common feed stocks for the manufacture of petrochemicals; these are :
1. Natural gas
2. Naphtha and reformed naphtha
Natural gas occurs in nature in association with petroleum. The major hydrocarbon
component of natural gas is methane. Naphtha is a fraction obtained during refining of
petroleum.
Some countries or industries prefer to use natural gas while some other use naphtha as a
starting material (feed stock) for the production of petrochemicals. The choice for the use of
natural gas or naphtha as feed stock by a particular country or industry depends upon the
availability of a particular feed stock or the availability of technology for the manufacture of
petrochemicals.
Primary Petrochemicals
Primary petrochemicals are the molecules obtained from the feed stock and are used to
manufacture petrochemical intermediates. Since the feedstock consists of natural gas, naphtha
and reformed naphtha, these give different primary petrochemicals.
Intermediate Petrochemicals and Derivatives
The petrochemicals obtained from primary petrochemicals by chemical reaction are
called (secondary) intermediate petrochemicals. Petrochemicals are also refered to as first
generation petrochemicals and second generation petrochemicals, First generation
petrochemicals are converted to second generation petrochemicals. These intermediate
petrochemicals may be put to some use or these may be further processed to get derivatives of
petrochemicals by a chemical reaction or a series of reactions to get products for other end
uses.
Down Stream Petrochemicals
The petrochemicals obtained from a given feedstock by a series of reactions are called
down stream petrochemicals. Down stream means that a particular petrochemical comes at a
later stage in the sequence of chemicals produced. For example in the following reaction.
Methyl alcohol is referred to as a down stream petrochemical.
Petrochemicals from Methane
Methane is the major hydrocarbon component of natural gas. CNG is the compressed
natural gas and LNG is the liquified natural gas. Moreover, methane is also obtained in large
quantities as a by product of petroleum refining.
The major petrochemicals produced from methane are:
1. Chlorinated products
2. Unsaturated hydrocarbons
3. Carbon black
4. Hydrogen
5. Methyl alcohol
Chlorinated products of methane
Methane is chlorinated to get methyl chloride (CH3CI), methylene chloride (CH2CI2),
chloroform (CHCI3) and carbon tetrachloride (CCI4). Most of the chlorinated products of
methane are used as a solvent.
Unsaturated hydrocarbons
Methane is cracked (by pyrolysis) with the help of suitable catalysts to get ethylene,
propylene and acetylene. These are used to get other products, which will be discussed later.
Carbon black
Methane is converted into carbon black (a form of carbon) by pyrolysis (cracking) and
Chemistry and Industry hydrogen is obtained as a by product. Carbon black is used as a black
pigment in manufacture of black printing ink and in rubber tyre industry.
Hydrogen
Hydrogen obtained by pyrolysis of methane is used for the manufacture of ammonia
gas. Ammonia is used as a raw material for manufacture of urea (a fertilizer), ammonium
nitrate and several other products.
Methyl alcohol
Methane is converted into methanol (methyl alcohol, CH3OH) by catalytic oxidation.
Methyl alcohol (methanol is further oxidized to get formaldehyde. Formaldehyde is an
important raw material for number of useful products, for example phenol-formaldehyde resins
(bakelite). Methyl alcohol is an important industrial solvent.
Petrochemicals from Ethylene
Ethylene is obtained by pyrolysis of natural gas or from naphtha by cracking. Ethylene is
an unsaturated hydrocarbon and has a carbon-carbon double bond. Therefore, ethylene is very
reactive and can be converted to a variety of petrochemicals and useful end products.
The major petrochemicals produced from ethylene are:
1. Ethyl alcohol
2. Ethylene oxide
3. Ethylene glycol
4. Dichloroethane
5. Vinyl chloride
6. Polyethylene
7. Ethyl benzene
Ethyl Alcohol
Ethyl alcohol (ethanol) is made by hydration of ethylene. Ethyl alcohol is used as a
solvent and a raw material for the manufacture of acetic acid, ethyl acetate and a large number
of other useful products.
Ethylene Oxide
Ethylene is oxidized to ethylene oxide with air or oxygen in the presence of a catalyst. It
is a raw material for the manufacture of ethylene glycol, which is a starting material for the
manufacture of polyester.
Ethylene Glycol
Ethylene glycol ( 1,2-dihydroxyethane) is manufactured by starting with ethylene. There
are several methods by which ethylene is converted to ethylene glycol. Glycol is used as an anti
freeze in automobiles. Ethylene glycol is an important starting material for the manufacture of
polyester.
Dichloroethane
Dichloroethane (1,2-dichloroethane) is made from ethylene by the reaction of chlorine.
It is used as a starting material for several other raw materials like ethylene glycol, vinyl
chloride, etc.
Vinyl Chloride
Vinyl chloride is made directly from ethylene or is made from ethylene dichloride.
Polyethylene
On polymerization ethylene gives polyethylene (polyethene), which is an important
plastic material.
Ethyl Benzene
Ethylene reacts with benzene in the presence of a suitable catalyst to give ethyl
benzene. Ethyl benzene is converted to styrene. Styrene is a raw material for the manufacture
of important plastic material polystyrene.
Petrochemicals from Propylene
Propylene is obtained by pyrolysis of natural gas or by cracking of naphtha. Propylene is
an unsaturated hydrocarbon.
The main petrochemicals produced from propylene are:
1. Iso-propyl alcohol
2. Polypropylene
3. Cumene (isopropyl benzene)
4. Glycerol
Petrochemicals from Acetylene
Acetylene (ethyne) is obtained by pyrolysis of natural gas. It is an unsaturated
hydrocarbon. It has a carbon-carbon triple bond. It is highly reactive in nature. The major
petrochemicals produced from acetylene are:
1. Vinyl chloride, vinyl acetate and acrylonitrile
2. Acetaldehyde
Petrochemicals from Butadiene
1, 3-Butadiene is obtained from naphtha by cracking. It is a diene, that is, it has two
carbon-carbon double bonds. It is a monomer for polybutadine which is used as a substitute for
natural rubber. Butadiene and styrene on polymerization give a copolymer called BUNA-S.
Petrochemicals from Benzene
Benzene is obtained from reformed naphtha. Naphtha is subjected to catalytic
reforming (also called aromatization). In the process aliphatic hydrocarbons present in naphtha
are converted to aromatic hydrocarbons.
Important petrochemicals obtained from benzene are:
1. Ethyl benzene and cumene
2. Chlorobenzene
3. Nitrobenzene
4. Cyclohexane
5. Linear alkyl benzenes (LAB)
6. Branched alkyl benzenes (BAB)
