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The Intermediates
The most important petrochemical intermediates are olefins and aromatics.
OLEFINS are intrinsically reactive molecules thanks to their double bond. The smallest
of them, namely ethylene and propylene, are the largest-volume intermediates of
the industry, with 130 million tons of ethylene and 80 million tons of propylene
produced per year.
They are both reactive enough to be the direct precursors of long-chain molecules
called polymers, that are the base component of plastics and resins. They are also the
precursors of other chemical intermediates like, for instance, ethylene glycol used as
antifreeze for cars. Both are highly flammable gases.
That is why they are difficult to transport. They are actually mostly transported
onshore through gas pipelines and overseas in gas tankers.
The 2nd family of intermediates is the AROMATICS Benzene, Toluene and Xylenes,
together abbreviated as BTX. They are characterized by a single 6-carbon aromatic
ring.
BTX are liquid intermediates that cannot be readily converted into plastic polymers.
For this purpose, they need to be chemically modified further on into more reactive
molecules.
As liquids, they can be easily transported by any means and are subject to overseas
trading. All together, they represent currently an average yearly production tonnage
of over 110 million tons.
Heavier refining cuts such as heavy naphthas, diesel oil or atmospheric residues from crude
oil distillation can also be used as petrochemical feedstocks.
All these products from refineries and natural gas plants are made of fairly stable
hydrocarbons.
These specific conditions promote the high yield production of desired light olefins, such as
ethylene and propylene, but also some heavier olefins like butenes. Butadiene, another C4
molecule with 2 double bonds, is also produced. Methane and hydrogen are side-products.
Under more severe conditions, for instance at higher temperatures, side cyclization
reactions occur, yielding light aromatics. Benzene is the major aromatic produced this way.
Further side reactions generally lead to the formation of carbon deposits, called coke.
The cracked gases are then cooled rapidly in a heat exchanger to stop any further reaction.
Some fuel oil is first extracted at around 200C from the bottom of a first separation tower
called primary fractionator.
All the steam used in the process is subsequently condensed in a second column called the
water quench column at between 35 to 80C. A C5 to C10 aromatic-rich gasoline cut named
pyrolysis gasoline is also condensed at this step and extracted from the process.
The remaining uncondensed gases leaving the top of the water quench column are then
recompressed, refrigerated and fractionated in a battery of distillation columns. All these
steps are called cold separation and cover temperatures from -100 to +100C and
pressures from 30 down to 5 bars.
From this cold separation train are separated raw ethylene, propylene, butenes and
butadiene, as well as some more pyrolysis gasoline.
All these raw intermediates require further purification treatments in order to meet the
commercial specifications of the market.
Ethylene Sourcing
Regarding more specifically ETHYLENE, it is almost exclusively produced from steam-crackers
fed with ethane or naphtha. Ethane crackers are located mainly in the US and in the MiddleEast where gas feedstocks are available. Naphtha crackers are located mostly in Europe, and
Asia.
Refinery Propylene
We have just seen that propylene is only a co-product of ethylene production from naphtha
crackers. Its demand has however largely outpaced the demand for ethylene, especially
because of the great success of polypropylene plastics.
W4V23 Feedstocks to Intermediates p. 6
IFPEN - IFP School 2015 / TOTAL SA 2015 / IFP Training 2015
As seen previously a partial solution to the world propylene supply gap is Refinery
Propylene, that is to say propylene from Fluid Catalytic Cracking.
To conclude, all these processes lead to small reactive molecules that can be used to make
long-chain products by what we call polymerization reactions. These products, which are
called polymers, are the base materials of an incredibly wide variety of plastics.
W4V23 Feedstocks to Intermediates p. 7
IFPEN - IFP School 2015 / TOTAL SA 2015 / IFP Training 2015