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C3-Based Petrochemicals: Recent Advances in Processes and Catalysts

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Catalysis for Clean Energy and Environmental Sustainability

Abstract

The petrochemical and chemical industries are key enablers of modern societies. Transportation, construction, packaging, food processing, textile, water distribution, medical equipment, and in various other sectors petrochemicals and chemicals are used in making products for improving the quality of our modern living. Among the major five types of feedstocks (as listed below), light olefins are the most important chemical building blocks for the production of the various downstream petrochemicals.

  • Light olefins: ethylene and propylene

  • C4 hydrocarbons: Butanes, butenes, butadiene

  • Aromatics: Benzene, toluene, and xylenes (BTX)

  • Long-chain n-paraffin: Kerosene-derived C9-C17 paraffins

  • Syngas: a mixture of carbon monoxide and hydrogen

Ethylene and propylene are two major light olefins, used as key petrochemical building blocks. Ethylene is used in the production of polyethylene, ethylene chloride, ethylene oxide, etc. These products are used in the construction and packaging, plastic processing, and textile industries, to name just a few examples. Similarly, propylene, the simplest C3 olefin, is used in making a number of useful derivatives such as polypropylene, propylene oxide, acrylonitrile, acrylic acid, cumene, isopropanol, etc. The global propylene demand was around 100 MMTA (million metric tons per annum) in 2015 which is expected to increase at a 3.6% CAGR (compound annual growth rate) to more than 140 MMTA by 2025 due to wider applications of the propylene derivatives in the consumer market. For instance, polypropylene, a key derivative of propylene, is one of the best-selling plastics, extensively used in automobiles and in the manufacturing of packaging films. Acrylonitrile, another propylene derivative, is used in making acrylic fibers and coatings. Similarly, propylene oxide is used extensively for the manufacturing of polyurethanes and other chemicals, acrylic acid and oxo alcohols are employed in PVC plasticizers and coatings-based applications, cumene is used to make epoxy resins and polycarbonate, and isopropyl alcohol is used as solvent, and so on. Not only plastic processing, but also the packaging industry, the furnishing sector as well as the automotive industries are the major consumers of propylene derivatives.

Propylene is a highly activated synthetic molecule and thus it needs to be converted selectively to its derivatives for their cost-effective production. Both propylene production and its selective conversion processes for the production of other chemicals have gone through important improvement in recent times. Thus, it is being felt that it would be interesting to capture the most recent advances in the processes and catalysts associated with propylene production and subsequent conversion of propylene to important C3 chemicals to global readers. The main aim of this book chapter is to bring important aspects of various commercial processes and catalysts involved in the production of propylene and propylene-derived chemicals namely, propylene oxide, acrylonitrile, isopropanol, and acrylic acid. About two-thirds of global propylene is consumed to make polypropylene (PP), which is one of the most versatile plastic materials with good mechanical and chemical properties. However, information related to polypropylene production technologies and associated catalysts is beyond the scope of this chapter.

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Abbreviations

2-EHA:

2-Ethyl hexyl acrylate

3-HP:

3-Hydroxy propionic acid

ABS:

Acrylonitrile-butadiene styrene

ACN:

Acrylonitrile

atm. :

Atmospheres (unit for pressure)

CAGR:

Compound annual growth rate

CARENA:

Catalytic reactors based on new materials

Conv.:

Conversion

DCC:

Deep catalytic cracking

DIPE:

Diisopropyl ether

DME:

Dimethyl ether

DTP:

Dominant technology for propylene production

EBHP:

Ethylbenzene hydroperoxide process

ECH:

Epichlorohydrin

EPS :

Expanded polystyrene foam

FCC:

Fluid catalytic cracking

GTO:

Gas to oil

HPPO:

Hydrogen peroxide-to-propylene-oxide

IPA:

Isopropyl alcohol

LPG:

Liquefied petroleum gas

MMTPA:

Million metric ton per annum

MTO:

Methanol to olefin

MTP:

Methanol to propylene

OCP:

Olefin cracking process

OCT:

Olefin conversion technology

PDH:

Propane dehydrogenation

PEM:

Proton exchange membrane

PO:

Propylene oxide

POC:

Propylene oxide cumene only

R2P :

Residue to propylene

R2R:

Reactor-2-regenerators

RFCC:

Resid fluid catalytic cracking

SAN:

Styrene-acrylonitrile resin

SAP:

Super absorbent polymer

SOEC:

Solid oxide electrolyzer cell

T :

Temperature

t :

Time

TBHP:

Tertiary butyl hydroperoxide

TSC:

Thermal steam cracking

USY zeolite:

Ultra stable Y zeolite

wt%:

Weight percentage

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  1. Corporate R&D Centre, Bharat Petroleum Corporation Limited, Greater Noida, Uttar Pradesh, India

    Chanchal Samanta & Raj Kumar Das

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  1. Department of Chemical Engineering, Indian Institute of Technology Delhi, New Delhi, Delhi, India

    K. K. Pant

  2. Department of Civil Engineering, Indian Institute of Technology Delhi, New Delhi, Delhi, India

    Sanjay Kumar Gupta

  3. Department of Chemical Engineering, Indian Institute of Technology (ISM) Dhanbad, Dhanbad, Jharkhand, India

    Ejaz Ahmad

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Samanta, C., Das, R.K. (2021). C3-Based Petrochemicals: Recent Advances in Processes and Catalysts. In: Pant, K.K., Gupta, S.K., Ahmad, E. (eds) Catalysis for Clean Energy and Environmental Sustainability. Springer, Cham. https://doi.org/10.1007/978-3-030-65021-6_5

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