Disseminated Document
A Study on Energy Efficiency Index in
Petrochemical Industry
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AStd E Effii Id i
Disseminated Document
A

St
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Petrochemical Industry
DepartmentofAlternativeEnergyDevelopmentandEfficiency(DEDE)



AStudyonEnergyEfficienc yIndexinPetrochemicalIndustry



Petrochemical Industry is one of the most important primary industries to
Thailand’seconomicdevelopment.Itisthefoundationofwidevarietyof industrial production
processes such as plastic and container industry, textile industry, rubber industry, agricultural
and fertilizer industry.These industries help create tremendous value added to Thailand
exporting sector.In 2006, the exporting values of upstream, intermediate and downstream
petrochemicalproductsare27,694,41,729 and 15,1468millionBaht,respectively.Inaddition,
the country also savesmillions of bath peryearon importing goods.The utilization of natural
gasintheprocessisalsoarightdirectiononincreasethevalueoflocallyavailablerawmaterial
which, in turn, benefit to Thai’s economy and society as a whole.Continued expansion of this
industrialsectorisforeseeableinthefuture.
Production process of petrochemical industry is considered one of the most energy
intensiveoperations.Duetoincreaseenergyconsumptiontrendofthisindustryandtocorrectly
accommodate the future economic expansion, it is important to facilitate this industry to
efficientenergymanagementinitiativesin orderto optimizethewholeprocesswhilemaximize
thebenefit.Inadditiontothegainfromenergyconservationandhigherenergyefficiency,this
willenhancethecapabilityofthe industrytocompeteonthe globalscale.Fromthese reasons,
the Department of Alternative Energy Development and Efficiency (DEDE), a responsible
governmental body who oversee the industrial energy management, considers this important
strategy and duty to promote the increase in energy efficiency of petrochemical industry. The
activitieswillbecarriedoutundertheEnergyConservationandPromotionActsof1992.
One strategy which the Department of Alternative Energy Development and Efficiency
has been executed to urge the industry about the energy efficiency is the analysis of energy
usage per production unit (Energy Index, EI).Hence it is DEDE’s initiative to develop Energy
Consumption of Petrochemical Industry in Thailand project to use the energy consumption
data of this industry as a step to develop energy benchmarking standard. Moreover, the
acquired information may be evaluated for preparation of energy efficiency index and energy
conservation of each manufacturer. Finally, the outcome of this project may lead to the right
directionondefiningtheappropriatefutureplanforenergyconservationplanofpetrochemical

industry.
Thisreport istodistributetheresultofthisprojectwhichincludestheanalysisofenergy
consumption index of petrochemical industry, approach on promotional plan for energy
conservation, and techniques for efficient energy usages. Authors hope that this report will
furtherbemoreorlessusefultostakeholdersandanyinvolved parties.
PREFACE

DepartmentofAlternativeEnergyDevelopmentandEfficiency(DEDE)


AStudyonEnergyEfficienc yIndexinPetrochemicalIndustry
CONTENT

PREFACE



CHAPTER 1: OVERVIEWOFTHAILANDPETROCHEMICALINDUSTRY 1
1.1ThePetrochemicalIndustryStructure
1
1.2TypesofPetrochemicalIndustry
4
1.3PetrochemicalFeedstock
6
1.4HowPetrochemicalIndustryAffectsEconomicSystem
7
1.5EnergyConsumptionofPetrochemicalIndustryinThailand
12
CHAPTER 2 :ENERGYCLASSIFICATIONOFPETROCHEMICALINDUSTRY 14
2.1ClassificationofPetrochemicalIndustry

14
2.2ProductionProcesses
15
CHAPTER3:ENERGYCONSUMPTIONINPETROCHEMICALINDUSTRY 22
3.1EnergyConsumptionIndex
22
3.2SpecificEnergyConsumption(SEC)
23
3.3 EvaluationofEnergyIntensity(EI)
29
CHAPTER 4:THEPROMOTIONOFENERGYCONSERVATION 31
4.1ProblemsinPetrochemicalIndustry
31
4.2SWOTAnalysis
32
4.3PromotionalPlanforEnergyConservationInThePetrochemical
33
CHAPTER5:TECHNOLOGYANDMEASURESFORENERGYCONSERVATIONIN
PETROCHEMICALINDUSTRY
36
5.1DevelopmentandImprovementofProductionTechnology
36
5.2EnergyEfficiencyImprovementforProcessesandEquipments
40
SUMMARY 48
REFERENCES 50
LISTOFABBREVIATION 52


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1
DepartmentofAlternativeEnergyDevelopmentandEfficiency(DEDE)

AStudyonEnergyEfficienc yIndexinPetrochemicalIndustry
2
In general, the petrochemical industry uses raw materials from the petroleum industry
to manufacture products such as plastic resins, synthetic fibers, synthetic rubbers, surface
coating materials and various types of adhesives.These products are considered primary raw
materials for human beings’ basic consumption items, occupational tools and equipment, and
various amenities
 for mankind.Figure 2 shows the links between the petroleum industry and
petrochemicalindustry;Figure3showsthestructureofThailand’spetrochemicalindustry.








Figure2Thailandpetroleumandpetrochemicalne twork




S
o
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urce: PTIT, 2
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a
lIndustry
3
DepartmentofAlternativeEnergyDevelopmentandEfficiency(DEDE)

AStudyonEnergyEfficienc yIndexinPetrochemicalIndustry
4
1.2TypesofPetrochemicalIndustry
The petrochemical industry is classified into 3 main groups, on the basis of their
products(asshowninFigure4).
 UpstreamPetrochemicalIndustry
 IntermediatePetrochemicalIndustry
 DownstreamPetrochemicalIndustry




Figure4OverviewofThailandpetrochemicalindustry


1.2.1UpstreamPetrochemicalIndustry
Upstreampetrochemicalindustryisthe productionofpetrochemicalproductswhich are
feedstock for further production of other petrochemical products (intermediate and
downstream).Itconsists of 7 kinds of products,  or “the Seven Sisters”, which are divided into
thefollowing3groupsonthebasisoftheirmolecularstructure:
 Alkanegroup,which is methane‐based
 Olefingroup,whichisethylene‐based,propylene‐basedandMixedC
4
‐based
 Aromaticgroup,whichisbenzene‐based,toluene‐basedand xylene‐based

Supporting: Infrastructure, Logistic, HR, Finance, Rules& Regulations
Valuechain
component
Key
activities
• E&P
• Oil
Refinery
• Gas
separation
• Olefins
- Ethylene
- Propylene

• Aromatics
- Benzene
- Para-
Xylene
• Plastic Resins
Commodity
(PE, PP, PVC, PS, EPS,
PET)
Engineering
(PC, POM, PBT*, Nylon
6,6*, PMMA)
Synthetic Fibre
- Polyester
- Nylon 6
- Polypropylene
- Acrylic
Syn. Rubber/
Elastomers

- BR, SBR, EPDM*
Syn. Coating/
Adhesives

- PVA*, Silicone
• Compounding

• Olefins
- EDC/VCM
- EO**/EG**
- Oxo Alcohol*

- Acrylonitrile*
• Aromatics
- Ethylbenzene**
- Styrene
- Cyclohexane**
- Caprolactam
- Cumene/Phenol**
- PTA
-PA

Conversion
Industries

Downstream

Intermediate

Upstream

Oil & Gas
Note:
* No local production,
** Investment in progress
DepartmentofAlternativeEnergyDevelopmentandEfficiency(DEDE)



ASt udy onEnergyEfficiencyIndexinPetrochemicalIndustry
5
1.2.2IntermediatePetrochemicalIndustry

Intermediatepetrochemicalindustryusesupstreampetrochemicalproductsasfeedstock
and supplies todownstream petrochemical industry.Its products are groupedon the basis of
theirupstreampetrochemicals,asfollows:
 AlkaneIntermediates,namely, productsfromupstreammethane,suchasmethanolor
methylalcohol,formaldehyde,ammonia,phosgene,etc.
 Olefin Intermediates, namely, ethylene products such as ethylene dichloride, (EDC),
vinyl chloride monomer (VCM), ethylene oxide (EO), and ethylene glycol (EG),
propyleneproductssuchasoxoalcohol andacrylonitrile 
 Aromatic Intermediates, namely, benzene products such as ethyl benzene (EB),
styrenemonomer(SM),cyclohexane,carprolactam,andparaxyleneproducts,etc.


1.2.3DownstreamPetrochemicalIndustry
Downstream petrochemical Industry uses upstream or intermediate petrochemical
productsasfeedstocktomanufacturedownstreamproductsorendproductspriortoconversion
inotherindustries.Theyarecategorizedbyendproduct,asfollows:
 Plasticresins
 SyntheticFibers
 Syntheticrubbers
 SyntheticcoatingandAdhesivematerials
ดิบสําหรับการผลิตอุตสาหกรรมปโตรเคมี

DepartmentofAlternativeEnergyDevelopmentandEfficiency(DEDE)

AStudyonEnergyEfficienc yIndexinPetrochemicalIndustry
6
1.3PetrochemicalFeedstock
 Thereare2typesoffeedstockforthepetrochemicalindustry:naturalgasandnaphtha.
The selection of feedstock varies on the advantages and disadvantages in the access to the
feedstock,andthereforevariesfromonecountrytoanother.Forinstance,incountrieslikethe

USA,Canada,andtheMiddleEast,
productionofpetrochemicalsisfromnaturalgas,whereasin
Japan, Korea, Singapore, and Europe, which do not have natural gas, naphtha is used instead,
since it is sold in the world market and is easy to transport. In the case of Thailand, both are
used.Thetypeoffeedstockalso
determinesthe manufacturingprocessusedbymanufacturing
plants.Figure5showsfeedstocksourcesfortheindustry.




Figure5Petrochemicalfeedstock



Gas separation

Wetgas

Refinery

Crude oil
Condensate
Splitter

Condensate
Petrochemical
Feedstock
Refinedproducts
Petrochemical

Feedstock
Petrochemical
Feedstock
• Methane
• Ethane
• Propane‐Butane(LPG)
• NGL
• LPG
• Naphtha‐Gasoline
• GasOil–Kerosene,
Jet,Diesel
• FuelOil
• Bitumen
• Etc.
•
LPG
• Naphtha
• GasOil
•
LPG
• Naphtha
Drygas
Residue
DepartmentofAlternativeEnergyDevelopmentandEfficiency(DEDE)



ASt udy onEnergyEfficiencyIndexinPetrochemicalIndustry
7
1.4HowPetrochemicalIndustryAffectsEconomicSystem



1.4.1TheRoleofPetrochemicalIndustryinThailand
 Thepetrochemicalindustrybringsintremendous,uninterruptedrevenuetothecountry
as show inTable 1.In year 2006, total revenue from petrochemicalindustry exceed447.760
millionBahtwhichisequivalentto6‐percentofgrossdomestic product(GDP).Moreover,the
industry also generates important raw materials  for several downstream
industries such as
automachine,electricalandelectronics,cosmetics,agricultural,packagingandtextileindustries.
 The petrochemical industry has a significant effect on the development of the country
directlyandindirectly.Notonlydoesitaddvaluetooilandnaturalgas,butitisalsorelatedto
numerousotherindustriesas
showninFigure6,forexample,packaging,spareparts,electronic
parts,textile,construction,etc


Table1ValuesofThailand’spetrochemicalproduction


Source:PTITFocus,2005



 .
6.0%6.1%5.9%4.9%4.4%Compare to GDP
2.2%2.2%2.6%2.6%2.8%2.8%2.4%2.4%2.3%2.3%Compare to GDPCompare to GDP
160,257181,427182,829143,812128,458•Value Added of Petrochem. Ind.:
Exclude Import and Feedstocks
(MM Baht)
3.5%3.7%3.8%3.2%2.8%Compare to GDP

260,714264,231244,486188,578153,202•Net Revenue: Exclud e Import
Portion (MM Baht)
447,760432,645382,500290,150239,060• Total Revenue (MM Baht)
Petroche mical Status
7,423,918 7,104,2286,503,4885,928,9755,450,643GDP: Current Price (MM Bah t)
25492548254725462545
6.0%6.1%5.9%4.9%4.4%Compare to GDP
2.2%2.2%2.6%2.6%2.8%2.8%2.4%2.4%2.3%2.3%Compare to GDPCompare to GDP
160,257181,427182,829143,812128,458•Value Added of Petrochem. Ind.:
Exclude Import and Feedstocks
(MM Baht)
3.5%3.7%3.8%3.2%2.8%Compare to GDP
260,714264,231244,486188,578153,202•Net Revenue: Exclud e Import
Portion (MM Baht)
447,760432,645382,500290,150239,060• Total Revenue (MM Baht)
Petroche mical Status
7,423,918 7,104,2286,503,4885,928,9755,450,643GDP: Current Price (MM Bah t)
25492548254725462545
Note: B.E. 2549 estimate GDP growth 4.5%, FX = 38 Bath/$

2002 2003 2004 2005 2006
2006
DepartmentofAlternativeEnergyDevelopmentandEfficiency(DEDE)

AStudyonEnergyEfficienc yIndexinPetrochemicalIndustry
8









Source:PTITFocus,2005

Figure6 Downstreampetrochemicalproductionvalues


In addition to producing ample supplies for domestic demand, in 2005 the
petrochemicalindustryhadmorethan200,000millionBahtwo rthofsurplusoutputforexport,
or4.85percentofthecountry’sexportvalue.


DepartmentofAlternativeEnergyDevelopmentandEfficiency(DEDE)



ASt udy onEnergyEfficiencyIndexinPetrochemicalIndustry
9


Source:PTITFocus,2005

Figure7 valuesgeneratedbynaturalgasyear2005


 Figure7showsthatthepetrochemicalindustry,whichuses only11.3percentofnatural
gas, generates as much revenue as 158,277 million Baht., whereas electricity industry, which
uses79.6percentofnaturalgas,generates 197,899millionBaht.Inotherwords,

revenuefrom
petrochemical industry is approximately 80 percent that of electricity generation, but
petrochemical industry uses only 14 percent of the volume of natural gas used in generating
electricity.This is the reason why Thailand must conduct a serious study and continue to
developpetrochemicalproducts.

Values Generated by Natural Gas – B.E. 2548
Incremental
values forgone
if indigenous
gas not used,
and import
fuel instead
Incre mental
values forgone
if indi genous
gas not used,
and import
fuel instead
4
1
4
,
8
2
8
6
6
,
4

0
0
1
8
3
,
6
7
6
Value lost
if import fuels
(1 94, 89 9 - 1 83,67 6 = 11 ,223
electricity - imported fuel = val ue add ed)
Value lost
if import fuels
(19 4, 899 - 18 3, 676 = 11, 22 3
electricity - impo rted f uel = val ue a dd ed )
Gas Used
790,080
MMSCF
(excl. LPG for feedstock)
Unit: Million Baht
• Industry Value
– Electricity
– E&P
– Petrochemical
–LPG
Gas Prod.
835,743
MMSCF

79.6%
100.0%
11.3%
9.1%
Direct
Financial
Benefit
Economic
Multiplier
194,899
230,749
- 100,576
(NG)
- 57,701
(Condensate)
25,802
9
9
9
9
• Government Take
– Income Tax - E&P 36,957
– Royalty - E&P 29,443
*
158,277


ValuesGeneratedbyNaturalGasYear2005
DepartmentofAlternativeEnergyDevelopmentandEfficiency(DEDE)


AStudyonEnergyEfficienc yIndexinPetrochemicalIndustry
10
1.4.2PetrochemicalProduction
1) Production
• ProductionCapacity
In 2006 production capacity of Thailand’s petrochemical industry was
19,000,000tons,comprising6.5milliontonsupstreamproducts,4.5million tonsofintermediate
products,and8.0milliontonsofdownstreamproducts,asshowninFigure 8.Itcanbeseenthat 
theindustryhascontinuouslyexpandedfromyear2002
onward,withatotalof4.0milliontons
growthbetweenyears2002and2006.


Figure8Thailandpetrochemicalproductioncapacity

• ProductionandProductionRate
Thailand produced nearly 16,000,000 tons of petrochemical products in 2005
and was then expecting more than 16,000,000 tons for 2006 (Figure 9).In downstream

industries,theproductionincreasedhighestfromyears2005duetothenewdownstreamplants
havebeenstartedtoproduceinvariouspetrochemicalsubstan ceforexamplecyclohexaneand
PTA.TheIntermediateproductsalsoillustratedanincrease,whileupstreamproductsdecreased
duetohaltinoperationforthepurposeofmaintenanceand
repair.

B.E.2549 is estimation data
2545 2546 2547 2548 25 4 9
2002
2003
2004

2005 2006
DepartmentofAlternativeEnergyDevelopmentandEfficiency(DEDE)



ASt udy onEnergyEfficiencyIndexinPetrochemicalIndustry
11

  N.B.Years2006approximatedvalues.

Figure9Productionvolumeofpetrochemicalproductsfromyears2002to2006(PTIT)




Table2AverageoperationcapacityofThailand‘spetrochemicalindustryfromyears2003‐2006

Petrochemical
Industry
CapacityAverage(%)
2002 2003 2004 2005 2006
Upstream 89 99 98 94 90
Intermediate 85 98 100 90 81
Downstream 86 87 88 86 85
Source:PTIT,2006

Upstreamandintermediatepetrochemicalproductionhadanaverageof90‐95percent,
while downstream production had 85 percent of production capacity.In 2006 downstream
productionslightlydecreaseasnewlyset‐upfacilitieswerenotoperatinginfullyet.
Analyses of recent periods have found that production and marketing have been

growingsatisfactorily,andwillcontinuetorise.Theliberalizationofpetrochemicaltradeduring
the past decade plus the country’s managing to sail through the 1997 economic crisis have
helped strengthened the Thai entrepreneurs, who saw the need to unite to increase their
businesspotential.Marketshaveexpandednoticeably,bothdomesticallyand
abroad.

Thailand Petrochemical Production
0
2,000
4,000
6,000
8,000
10,000
12,000
14,000
16,000
18,000
2545 2546 2547 2548 2549
KTA
Upstream Intermediate Downstream

2002
2003
2004
2005 2006
DepartmentofAlternativeEnergyDevelopmentandEfficiency(DEDE)

AStudyonEnergyEfficienc yIndexinPetrochemicalIndustry
12
1.5EnergyConsumptionofPetrochemicalIndustryinThailand

Thepetrochemical industry relies heavily onenergy.Withitspresentgrowthrate,and
ascompanies are also constantly trying  to expand their production, consump tion of electricity,
gas and fuels will increase unavoidably, no matter how much emphasis is given to energy
conservation.

1.5.1Energyconsumption
From the data compile d from 30 plants producing upstream, intermediate and
downstream petrochemicals, the study has found that consumptionofenergyis highest in the
upstreamindustry,(datafromalltheplantsinThailand)asshowninTable3

Table3EnergyconsumptioninThailand’spetrochemicalindustry
Petrochemical
Industry
Audited
Plants(%)
EnergyUse (Ktoe)
Year2005 (%) Year2006 (%)
Upstream 100 2,172
68.91 2,186 64.48
Intermediate 43 213 6.76 475 14.01
Downstream 32 768 24.33 729 21.50
Total 3,152 100.00 3,390 100.00

However, energy consumption of the country’s entireindustrial sector, including food,
drinks, textiles, wood, chemicals, pap er, ceramic, cement and metal (referred from energy
consumption data from DEDE’s energy consumption annual report), was selected to compare
the energy used in the petrochemical industry.It was found that the petrochemical sector
consumes
15to17percentofthetotalindustrialsector’sconsumption.


DepartmentofAlternativeEnergyDevelopmentandEfficiency(DEDE)



ASt udy onEnergyEfficiencyIndexinPetrochemicalIndustry
13
Electricity
6%
Steam
38%
Natural Gas
42%
LPG 0.6%
Diesel
0.6%
Fuel Oil
1.7%
Others
11.1%
1.5.2ProportionofEnergyConsumptioninPetrochemicalIndustry
Consumptiondatacompiledfromselectedmanufacturingplantsin2006showsthemain
energiesusedinthemanufacturingprocessofproductsconsistsofelectricity,steam,naturalgas
(NG),liquidpetroleumgas(LPG),dieseloil,fueloil,andothers(processoff‐gas,fuelgas,etc.)as
showninTable4andillustratedin
Figure10
Table4ProportionofEnergyConsumption(%)
EnergyType Ratio(%)
**

NaturalGas 42.0

Steam 38.0
Electricity 6.0
Fueloil 1.7
Dieseloil 0.6
LPG 0.6
Others (Processoff‐gas,Fuelgas, etc.)
11.1
Total 100
**estimationvaluefromparticipatingpetrochemicalplant


















Figure10 Proportionofenergyconsumptioninyea r s 2006

As shown above, natural gas is the topmost energy being used in petrochemical

production(mostlyasdirectfuelfortheoven,ordirectheat),whilestreamissecondinquantity.
Othertypesofenergy,alsoestimatedfrom
consumptionintheproductionprocess,areusedat
smallerquantities.
DepartmentofAlternativeEnergyDevelopmentandEfficiency(DEDE)

AStudyonEnergyEfficienc yIndexinPetrochemicalIndustry
14


2.1ClassificationofPetrochemicalIndustry
The petrochemical industry covers a vast array of products, and the manufacturing
processesvaryfromoneproducttoanother.Sometimesthesameproductsusedifferentinraw
materials, technological processes, and even different equipment.For this reason, energy is
usedinvaryingamounts.
However, from this study, in which consumption of
 energy is compared using
internationalbasis,theindustryisclassifiedonthebasisofproductionprocess,withtheaimto
presentananalysisofindicesofenergyconsumptionwhicharecorrect,suitableand beneficial
butwithoutharmingtheexistingplantsfromwheredataweregiven.Thestudyresultwill reveal
overall facts and figures of each group as a whole, and not of individual  products.This is
because there are not too many petrochemical plants in Thailand, and presenting too detailed
datamayberevealingconfidentialinformationofthebusinesses.


Therefore,petrochemicalindustryweredividedinto3groupsasfollows:



 UpstreamPetrochemicalIndustry)

- OlefinsGroup
- AromaticsGroup
 IntermediatePetrochemicalIndustry
 DownstreamPetrochemicalIndustry
- HDPE
- PS,PP,EPS
- EmulsionPVC,ABS,SAN, PC
2.CLASSIFICATIONOFPETROCHEMICALINDUSTRY
DepartmentofAlternativeEnergyDevelopmentandEfficiency(DEDE)



ASt udy onEnergyEfficiencyIndexinPetrochemicalIndustry
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1) CrackingProcess
Crackingisaprocessinwhichmoleculesofrawmaterialaredissociatedintosmaller
ones.Therearetwotypesofcrackingprocess,thermalsteamcrackingandcatalyticcracking.
2.2ProductionProcesses

2.2.1UpstreamPetrochemicalProduction
Upstreampetrochemicalindustrialprocessaimsatproducingprimaryfeedstockforthe
nextgroupofproducts.ItsproductionprocessisshowninFigure11‐13(source:PTIT2006),with
7majorproducts,namely,methane,ethylene,propylene,MixC
4
benzene,tolueneandxyleneas
the basic chemicals for further petrochemical development.There are 2 major processes, as
follows:
ThermalSteamCracking
Steamcracking is the dissociation of raw
material such as  ethane and propane

yielding important petrochemical products,
ethyleneandpropylene,mixedC4,pyrolysis
gasoline. Methane and hydrogen are also
someofmajorby‐products.
CatalyticCracking
Dissociation of larger, stable molecules
requires catalysis. Refinery products such
as gasoil and fuel oil may be passed
throughcatalyticcracker toobtaingasoline
and diesel as major products and by ‐
product, propylene, which is primary
petrochemicalproduct.
2) ReformingProcess
Reforming of hydrocarbon structure may be accomplished by the use of heat,
pressure and/or catalyst in order to obtain desired products. This process converts heavy
naphthatoaromaticssuch asbenzene,tolueneandxyleneaswellashydrogenasby‐product.
Reformingmaybecarriedoutby
severalfollowingmethods.
 Dehydrogenation is a process in which hydrogen atoms are being taken away from
saturated hydrocarbons structure leaving product of unsaturated hydrocarbons such as
thedehydrogenationofcyclohexan etoaromatics.
 Dehydrocyclization is a process in which hydrogen atoms  are being taken away from
aliphatichydrocarbonsyieldingaromaticssuchasdehydrocyclization
ofparaffin.
 Dealkylationistheextractionofalkylgroupfromtolueneandxyleneyieldingbenzene.
 Transalkylation or Disproportionation is the combination process of two molecules
resulting in two new molecules  which are bigger and smaller than precursor ones i.e.,
catalytictransalkylationoftoluenetobenzeneandxylene.

Isomerization involves themolecular restructuring of material whileretaining the same

numberofatomsi.e.,isomerizationofo‐xyleneandm‐xylenetop‐xylene.
DepartmentofAlternativeEnergyDevelopmentandEfficiency(DEDE)

AStudyonEnergyEfficienc yIndexinPetrochemicalIndustry
16
Figure 11Productionprocessesofmethane,ethylene,propyleneandmixed‐C4fromNGor
propane
Figure 12Productionprocessesofmethane,ethylenepropyleneandmixed‐C
4
fromnaphthaor
gasoil
Figure 13Productionprocessesofbenzene,tolueneandxylene
DepartmentofAlternativeEnergyDevelopmentandEfficiency(DEDE)



ASt udy onEnergyEfficiencyIndexinPetrochemicalIndustry
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2.2.2IntermediatepetrochemicalProcess
Intermediate petrochemical industrial process uses upstream productsas feedstock for
downstream production industry. Intermediate products can be divided into the following
classes:
 OlefinIntermediates
 AromaticIntermediates
 AlkaneIntermediates
Theproductionprocess of Intermediate petrochemical is complex and differs from one
producttoanother.Itisalsorelateddirectlytodownstreamprocess.SeeFigure14‐16




Figure 14ProductionprocessofVinylChlorideMonomer(VCM)





Figure 15Productionprocessof StyreneMonomer(SM)

DepartmentofAlternativeEnergyDevelopmentandEfficiency(DEDE)

AStudyonEnergyEfficienc yIndexinPetrochemicalIndustry
18
Figure 16Productionprocessof PureTerephthalicAcid(PTA)


2.2.3DownstreamProduction
Downstream petrochemical industrial process relies on upstream and intermediate
production process in producing what is to be converted to final products.Downstream
productscanbegroupedasfollows:
 PlasticResins,composeof
• CommodityPlastics
• EngineeringPlastics
• HighPerformancePlastics
 SyntheticFibers
 SyntheticRubbers,Elastomers
 SyntheticCoatingandAdhesiveMaterials
Polymerization is a major process for production of downstream petrochemicals. This
process involves the combination of monomers into long chain polymer.Typically,
polymerization process requires the use of catalysts, heat and pressure in order to achieve
completereactions.Polymerizationmaybeperformedbyseveralmethodssuch

as:
 Gasphasepolymerizationunderhighpressureandtemperature
 Solutionphasepolymerizationunderhighpressureandtemperature
 Bulkor batchpolymerizationundermoderatepressureandtemperature
 Suspensionpolymerization undermoderatepressureandtemperature
 Emulsion polymerizationundermoderatepressureandtemperature
DepartmentofAlternativeEnergyDevelopmentandEfficiency(DEDE)



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Figure 17Productionprocessof LDPE


Figure 18Productionprocessof LLDPEbysolutionphasepolymerization



Figure 19Productionprocessof LLDPEbysolutionphasepolymerization

DepartmentofAlternativeEnergyDevelopmentandEfficiency(DEDE)

AStudyonEnergyEfficienc yIndexinPetrochemicalIndustry
20
Figure 20Productionprocessof PVCbysuspensionpolymerizatio n 


VCM

RawMaterial
PolymerizationReactor
Slurry
Stripper
Latex
Storageand
Seiving
Dryer Classifier
Storage
Packing
PVCResin
RawMaterial
Storageand
Preparation
VCM
Recovery
Grinding
Figure 21Productionprocessof PVCby emulsionpolymerization


Figure 22Productionprocessof PP
DepartmentofAlternativeEnergyDevelopmentandEfficiency(DEDE)



ASt udy onEnergyEfficiencyIndexinPetrochemicalIndustry
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Figure 23Productionprocessof PVCResin
Figure 24Productionprocessof PPbygasphasepolymerization


Figure 25Productionprocessof ABS
