Petrochemistry is a
fascinating science and an inventive business sector, constantly adapting
to new environments and meeting new challenges. Chemicals derived from
petroleum or natural gas - petrochemicals - are an essential part of the
chemical industry today. Even Petrochemistry is a fairly young industry,
it exists in our everyday life, from household goods (kitchen appliances,
textile, furniture) to medicine (heart pacemakers, transfusion bags), from
leisure (running shoes, computers) to highly specialized fields like
archaeology or crime detection.
However, all this is little known. Petrochemicals do not reach the final
consumers - they are first sold to production industries, undergo several
transformations, to become the functional products that you see and use
everyday.
It all begins with crude oil
(petroleum) and natural gas.
Crude oil and natural gas are extracted from the ground, on land or
undersea.
The Refinery
Then the refinery process started - to produce physical and chemical
changes in crude oil and natural gas. One of these processes is
distillation, i.e. the separation of heavy crude oil into lighter groups
(called fractions). One fraction, fuel oil, is used for heating or for
diesel fuel in automotive applications. Another one is naphtha, used in
gasoline and also as the primary source of petrochemicals.
The refining is where the job of the oil industry stops, and the job of
the petrochemical industry takes over.
The Cracking
Petrochemistry gets its raw material - known as feedstocks - from
the refinery: naphtha, components of natural gas such as butane, the
by-products of oil refining processes, such as ethane and propane. These
feedstocks are then processed through an operation that is known as
cracking.
Cracking is simply the process of breaking down heavy oil molecules into
lighter, more valuable fractions. In steam cracking, high temperatures are
used; when a catalyst is used it is known as catalytic cracking. The plant
of these operations are called cracker.
New products are obtained, the building blocks of the petrochemical
industry:
Olefins:
ethylene,
propylene,
C4 derivatives, including butadiene
aromatics - benzene, toluene and xylenes.
From Petrochemicals to Downstream Industries
These products (ethylene, propylene, butadiene, benzene, toluene, xylenes…)
are processed in petrochemical plants into more specialized products
- to be fit for use by the downstream industries. It takes only one
(complex) operation to go from ethylene to the well-known plastic
polyethylene, for example, but it takes more than seven to go from benzene
to the nylon used in our clothes and sports equipment!
In the end, petrochemicals will go into products that we are all familiar
with: plastics, soaps and detergents, healthcare products synthetic fibres
for clothes and furniture, rubbers, paints, insulating materials...
Petrochemicals in Our Everyday
Life
Healthcare
Petrochemistry makes a large contribution to the general health care and
hygiene.
Cumene
and phenol,
for example, are used as a starting material to make aspirin and
penicillin.
Some petrochemical resins
are used in drug purification process.
Petrochemica-derived plastics and resins are used in artificial joints and
limbs. Plastics are essential for making disposable syringes, containers
for storing blood or vaccines, and other apparatus.
Polymers
are now being widely used in medical technology, for example in heart
surgery, or for stimulators in eyes and ears.
High Technology
Petrochemistry has made possible the quantum leap achieved in
communication technology during the last decades. Many components in our
computers, telephones, TV sets, radios or CD players...In the electronics
field, petrochemistry is everywhere, from the board of a printed circuit
to the chip, cablings and connectors, digital cameras, mobile phones,
laptops...The computer could not function without microchips, made using
petrochemicals. In computer housings and computer keyboards styrenic
plastics are used.
Most of a CD consists of a piece of clear polycarbonate;
a plastic derived from benzene,
through bisphenol
A and cumene.
This polycarbonate is impressed with microscopic bumps arranged as an
extremely long spiral track of data, then covered with a thin aluminum
layer. Then a thin acrylic
layer is sprayed over the aluminum to protect it. The label is then
printed onto the acrylic... and slipped into a polystyrene
"jewel box", the transparent, plastic boxes in which CDs usually
come.
The electronic industry could not do without the materials derived from
the petrochemical industry: they ensure better design, better electrical
insulation and safety, ease of assembly and an amazing capacity for
miniaturisation and data storage.
Auto & Airplans: saving energy, improving
safety
Modern cars, buses or lorries and modern airplanes all rely on
Petrochemicals. If you removed all the components made from
petrochemical-based products, you would no longer be able to drive or fly
them.
Petrochemical products have become an integral part of the automotive
industry. their easy process ability helps reduce the vehicle assembly
time, and thus the costs. Thanks to their light weight, which invariably
translates into considerable energy savings.Colourfast durability, design
flexibility and light weight make petrochemical-based composites an
obvious choice for automotive bodies and components.
Have you ever wondered why cars do not explode in real life as frequently
seen in action movies? That is thanks to petrol (gasoline) tanks made of
High Density Polyethylene (HDP), which ensure additional safety in case of
accident through their outstanding shape-resistance. So the petrol was
prevented from leaking, a fire could not start. Petrochemical-derived
Synthetic rubber gives tyres better road-hugging ability, especially on
wet roads. Phenolic
resins are used in binders for friction materials in brakes and
clutches. Car and booster seats made from styrene-based
plastics that meet crash-test standards have helped reduce the death rate
in car accidents.
The antifreeze spray used on cars in winter is often produced using ethylene
glycol. Ethylene and propylene
glycols are also used in aeronautics and ensure safe take-off in spite
of bad winter weather conditions. The composites derived from
petrochemicals can save more than 30% of the weight of an aircraft
structure.
A warm and pleasant home
We rely on petrochemistry for foundation, wall and roof insulation foams
and fibres, pipes, window frames and fitted furniture. Because of the
durability of these materials, maintenance, such as painting, is minimized
and often removed completely.
As the importance of energy conservation grows, the need for highly
effective insulation materials also increases. Heating and cooling account
for 50 to 70% of the energy costs for the average home. The performance of
petrochemical-derived insulation materials can result in significantly
lower heating and cooling costs. And using more energy efficient materials
and products in our construction, to decrease the use of fuel and energy,
translates into reduced air pollution. After use, these materials can be
re-used, recycled or turned into a source of energy.
Our kitchen has
become a more pleasant, cleaner place. Working surfaces, shelves and
tables are resistant and easy to wash, thanks to the hygienic laminates
manufactured using petrochemicals. Non-stick frying pans are easy to use,
last for decades and do not need to be scrubbed, the cooker, the microwave oven and
the refrigerator are
amongst the numerous fixtures that are made from polymer
materials. Liquid detergents made from ethylene
make dish washing quicker and more hygienic. Most labour-saving
innovations, such as the food mixer, the plastic bin or cling film, are
fabricated from petrochemical
products.
Petrochemical-based food packaging has many virtual performance, low
cost, light weight, thermal insulation, shock-resistance, hygiene, safe and healthy.
Nowadays, most components of children's playhouses, infant bouncers,
changing tables, prams and tricycles are made from petrochemicals-derived
products.
Fabrics Clothing
We
expect our fabrics to be warm, light, easy to wash, easy to dry, and easy
to wear. Man-made fibres derived from petrochemicals can be varied to meet
these specific needs. Easy-care clothing, carpets, curtains and furnishing
fabrics are made of such fibres - or a mixture of man-made and natural
materials.
Acrylic
fibres, for example, expand the look and feel of jumpers to year-round
use and have a significantly longer wear life. Olefin
fibres are ideal for extreme-cold clothes, but are also used in artificial
turf for athletic fields, disposable nappies and housing insulation. Some
fibres, such as those commonly known as microfibres, such as superfine polyester,
nylon
or acrylic
fibres, are now used in clothes that have the feel, look and luxurious
touch of the most expensive silk.
A hygienic and pleasant bathroom
Nearly everything in our modern bathrooms depends on the output of the
petrochemical industry: plastics are the material of choice in bathroom
tiles, fixtures, fittings and shower curtains, for their hygienic
properties, durability, stylishness and easy maintenance.
Cosmetics and personal care products rely on high quality
packaging. The brilliant surface of styrene-acrylonitrile
(SAN), for example, has great depth of colour, looks good and feels
good – an important consideration in the bath where we surround
ourselves with pleasing things. SAN accepts print very easily and affords
diverse design possibilities. Moreover, SAN is resistant to chemicals. SAN
is also suitable for bathroom fittings and toothbrushes for example.
Indoor and outdoor leisure
Hobbies, sporting equipment and DIY materials have also benefited
considerably from petrochemistry. Fitness centres, athletic clubs,
swimming pools all rely heavily on petrochemistry for their fittings and
equipment. The DIY enthusiast has easy access to off-the-shelf paints,
varnishes, adhesives, household wiring etc. that come in handy packages,
guaranteeing a long life and a minimum of mixing and messing. Very often,
petrochemicals enter both into the products themselves and their
packaging. TV sets, radios, CD players, CDs (made from polycarbonate),
audio and videotapes, musical instruments depend on specialised
petrochemicals. Artists, both professionals and amateurs, use colour
pencils, paints and inks that have been manufactured thanks to the input
of the petrochemicals industry. Dyes and pigments are also essential for
colour printing, photography and dyeing. Some petrochemicals are used as
intermediates when manufacturing paints, like acrylic
acid or acetyls;
some are used as solvents that make paints flow and inks dry.
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