August 2009

Butanes
Cellulose Acetate and Triacetate Fibers
High-Density Polyethylene Resins
Major Amino Acids
Oxo Chemicals
Polyamide Resins (Nonnylon Types)
Sodium Carbonate
Sulfur
Ammonia from Natural Gas by the KBR Purifier Process
Polyphenylene Sulfide (PPS)
Chemweek's Business Daily
CEH Reports and Product Reviews in Preparation
PEP Reports Scheduled for 2009
SCUP Reports Scheduled for 2009

CEH Marketing Research Report Abstract
BUTANES
By Emanuel Ormonde with Masahiro Yoneyama

The global butanes business is operated by oil and natural gas companies from the public and private sectors. For most regions of the world, published information on butanes is usually included as part of statistics on the entire liquefied petroleum gas (LPG) stream.

LPG consumption is forecast to grow at an average annual rate of 2.5% per year in the next five years. This growth will be attributable to increased commercial/residential use throughout the world, as well as to increased use in the Middle East as a petrochemical feedstock. In terms of global supply, natural gas processing continues to be the largest supply source of LPG, accounting for close to 55% of total worldwide production in 2008. Refineries accounted for the remaining world production of LPG. In the next few years, LPG will also be recovered from LNG. Growth in LNG facilities around the world will increase LPG production.

Butane prices reached their highest levels ever in mid-2008 because of high LPG prices resulting from high crude oil and natural gas prices. In 2008, the average Saudi Arabian contract price for butane had risen by 72% since 2006. Average Japanese butane prices also rose by 65% since 2006. A considerable drop in butane price was noticed in late 2008/early 2009 due to the fall in crude oil prices caused by the global economic recession and financial collapse (crude oil price decreased as the speculative premium burst and demand weakened). The butane price actually reverted and stabilized to 2005 levels. Future butane prices will fluctuate according to the rise or fall of crude oil prices along with natural gas competition.

The following chart shows world prices for butane during 2000–2009:

Further regulations aimed at reducing emissions of volatile gasoline components into the environment are expected to become widely adopted (especially in the United States), thus somewhat reducing butane consumption that is directly blended into the gasoline pool. n-Butane can be isomerized to isobutane, which is then dehydrogenated to isobutylene. Isobutylene in turn is used to produce methyl-tert-butyl ether (MTBE), consumption of which had been growing strongly until about 2003. MTBE use in the United States is forecast to be completely phased out by 2013. The ban on MTBE is driven by concerns about groundwater contamination. Most MTBE units in the United States will be converted to produce iso-octene, or the refinery isobutylene normally used to produce MTBE will be used to produce C₄ alkylate for motor gasoline blending. Although the United States is reducing MTBE production and usage, MTBE will continue to show positive growth in other areas of the world, for example, in Asia and the Middle East.

China is currently the largest LPG producer and consumer in Asia. All of the LPG production in China is from the domestic refinery sector where existing refineries are being expanded and new refineries are being and have been built to accommodate the expanding economy and the demand for fuels in the region. LPG production in China is expected to grow by 5–6% per year from 2008 to 2013. Chinese growth in LPG demand has been relatively strong at an average annual growth rate of over 6% from 2000 through 2008. Future LPG demand is expected to grow positively, but not at the high growth rates of the past. The residential/commercial fuel sector will drive Chinese demand for LPG in the foreseeable future.

(For the complete marketing research report on BUTANES, visit this report’s home page or see p. 380.0000 A of the Chemical Economics Handbook.)

CEH Marketing Research Report Abstract
CELLULOSE ACETATE AND TRIACETATE FIBERS
By Thomas H. Banks

The global supply of cellulose acetate fibers is dominated by a relatively small number of companies, all of which are producers of cigarette filter tow. Some other companies produce textile fibers, but most have only small capacities compared with tow producers. The number of companies producing both tow and textile fiber has dwindled in the last ten years and continues to do so. Through 2008, only Eastman, Mitsubishi Rayon and SK Chemicals continued to produce both. The announcement in early 2009 of a joint venture between Eastman and SK Chemicals marks the end of textile fiber production in the Republic of Korea when the new Eastman Korea tow plant is opened in 2010. Textile fiber production in the Republic of Korea will be transferred to the Eastman location in the United States.

The worldwide economic slowdown in 2008 and continuing on into 2009 has had a very detrimental effect on the sales of cellulose acetate fiber for textile applications. Some of the smaller producers may have a difficult time staying in business unless the world’s economies make a strong positive turn in 2009 and cellulose acetate uses in apparel and home furnishings applications reverse historical directions. World textile fiber production capacity utilization in 2008 was at a level of 57%. At these levels of plant utilization it is difficult to maintain the viability of the business.

The following pie chart shows world consumption of cellulose acetate fibers:

Tar and nicotine levels in cigarette smoke are being mandated for further reduction in many parts of the world, leading to increased usage of filter tow. Cost reductions in the manufacture of cigarettes, for example smaller circumference, and mandated tar and nicotine reductions bringing about longer filters, continue to move the tow industry to the manufacture of lower total deniers, with a detrimental effect on capacities. Because of the restructuring of the cigarette industry toward lower-denier tow usage, the operating capacities of the tow producers will continue to drop from nameplate capacities. Improvement in dope preparation and the resultant dope quality may lead to slight increases in spinning speed, which will recover spinning capacity.

Areas of the world such as Asia Pacific, CIS, the Middle East and Latin America have had fewer laws and focused opposition to smoking. Most of the developing countries have little or no legislative control of cigarette consumption. While these factors are influencing smoking on a regional level, the expected result on a worldwide basis is that smoking will continue to grow, but at a slightly lower rate. Global cigarette production and consumption are predicted to continue to rise, despite the continued fall in world consumption per capita.

(For the complete marketing research report on CELLULOSE ACETATE AND TRIACETATE FIBERS, visit
this report’s home page or see p. 541.1000 A of the Chemical Economics Handbook.)

CEH Marketing Research Report Abstract
HIGH-DENSITY POLYETHYLENE RESINS
By Andrea V. Borruso

In terms of volume, HDPE is the third-largest commodity plastic material in the world, after polyvinyl chloride and polypropylene. The 2008 world consumption represented a global per-capita consumption of 4.4 kilograms.

As a result of the growth of the HDPE industry in China and the Middle East, a considerable share of HDPE production is now switching from traditional established economies in North America, Western Europe and Japan to production centers in Iran, Qatar and Saudi Arabia. In 2008, these emerging regions accounted for a combined 21% of world production and by 2013 will account for 31% of world production. On the demand side, China and the rest of Asia, excluding Japan, represented 16% of world demand in 2008 and by 2013 will represent almost 38% of world demand.

The following pie chart shows world consumption of HDPE:

Blow molding, injection molding, and film and sheet account for approximately 66% of the world market for HDPE, most of it being packaging, with the exclusion of blow-molded car gas tanks. Construction represents 10–15%, while another 10–15% is distributed among a myriad of consumer and industrial applications. These markets are influenced by business cycles and fluctuate in tandem with the economy. Future growth in world HDPE consumption will be driven by the status and progress of regional economies, continued substitution of traditional materials (e.g., glass, wood, concrete, paper) by HDPE, and avoidance and obsolescence of HDPE in some traditional applications. This latter factor will be more evident in the developed regions of the world, where continued improvements in polyolefin processes and catalyst technologies should allow for the production of very broad ranges of products and grades that will increase HDPE’s utility in the marketplace. HDPE will also face competition, not just from traditional materials such as other existing thermoplastics, but also from emerging polymers brought into the marketplace via new technologies such as metallocene catalysts.

(For the complete marketing research report on HIGH-DENSITY POLYETHYLENE RESINS, visit
this report’s home page or see p. 580.1340 A of the Chemical Economics Handbook.)

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CEH Marketing Research Report Abstract
MAJOR AMINO ACIDS
By Michael P. Malveda with Xiaomeng Ma, Stefan Mueller and Kazuteru Yokose

Amino acids are the building blocks of protein and are vitally important components of all living organisms. Amino acids for protein formation can be obtained directly (as such) by living organisms from the proteins in their diets; some can also be synthesized in vivo by some organisms from nitrogenous and other chemicals in their food supply.

There are over forty known amino acids, about twenty of which are actually contained in animal tissues. Ten of these are commonly recognized as being “essential” for monogastric (single-stomached) animals such as humans, poultry and swine; that is, they must be included in the diets of these species. Of these ten, only methionine and lysine have historically had commercial markets substantial enough to justify their synthesis and manufacture in large volume by the chemical industry; well over 90% of both products is used to supplement feed rations for poultry and swine. In the last several years, however, increasing attention has been focused on tryptophan and threonine for feed use, with new production capacity resulting.

This report covers the major amino acids used in animal feed throughout the world: methionine, lysine, threonine and tryptophan. Although the report discusses nonfeed uses, the main focus is on animal feed use. Methionine and lysine are the dominant amino acids used in animal feed, and recently, threonine and tryptophan (albeit at much lower volumes) have experienced high growth in animal feed use due to improved efficiency and reduced waste.

The following chart shows world consumption of the major amino acids by region:

Only four main companies produce methionine worldwide. In addition, there are more than a dozen minor methionine producers in China. The four companies—Evonik Degussa, Novus International, Adisseo and Sumitomo—together account for nearly 98% of world methionine capacity.

Lysine production is somewhat less concentrated on a global basis than is methionine. The top six producers account for 82% of capacity. China continues to dominate as the world’s largest lysine producing region, accounting for about 42% of the world’s lysine producing capacity.

The main producers of threonine are Ajinomoto, with 44% of total global production capacity, and Evonik Degussa (in Hungary and Slovakia), with 22% of the total. The world threonine market is expected to continue to grow at rapid rates from 2008 to 2013 (5–6% annually).

The main tryptophan producer is Ajinomoto; the company is estimated to account for about 70–80% of the world tryptophan market. The world tryptophan market is expected to continue to grow at a little over 1.5% per year from 2008 to 2013.
 

(For the complete marketing research report on MAJOR AMINO ACIDS, visit this report’s home page or see p. 502.5000 A of the Chemical Economics Handbook.)

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CEH Marketing Research Report Abstract
OXO CHEMICALS
By Sebastian N. Bizzari with Milen Blagoev and Akihiro Kishi

The oxo process or hydroformylation of olefins with synthesis gas is the principal route to C₃-C₁₅ aldehydes, which are converted to alcohols, acids or other derivatives. By far the most important oxo chemical is n-butyraldehyde, followed by C₆-C₁₃ aldehydes for plasticizer alcohols, isobutyraldehyde and C₁₂-C₁₈ aldehydes for detergent alcohols. Nearly all oxo aldehydes are converted to derivatives in plants adjacent to the hydroformylation unit; very small volumes of oxo aldehydes are transported.

Propylene-derived n-butyraldehyde and isobutyraldehyde account for nearly 73% of world consumption of oxo chemicals. High consumption volumes for both alcohol derivatives of n-butyraldehyde—n-butanol and 2-ethylhexanol (2-EH)—will continue in the near future; however, it is expected that n-butanol will surpass 2-EH consumption in 2009–2010. This is partly due to substitution of di(2-ethylhexyl) phthalate (DEHP), the main plasticizer derived from 2-EH, with other plasticizers derived from other plasticizer alcohols. C₆-C₁₃ plasticizer oxo alcohols have lost market share, primarily as a result of decreased production and consumption of C₇, C₉ and C₁₁ linear alcohols; they are expected to continue to lose market share, largely as a result of increased production and consumption of 2-propylheptanol (2-PH), which is derived from valeraldehyde. World consumption of valeraldehyde will grow at the highest rate of all oxo chemicals, largely as a result of the commissioning of 2-PH capacity in Europe and China starting in late 2009 and continuing into 2013.

The following pie chart shows world consumption of oxo chemicals:

Demand for oxo chemicals in the United States is expected to grow moderately, at an average annual rate of almost 2% during 2008–2013. The long-term prospects for oxo chemicals in Western Europe improved considerably during 2005–2008, as consolidations and capacity reductions resulted in improved efficiencies and capacity utilization. The commissioning of plants for 2-PH and additional isononyl alcohol (INA) capacity helped reduce the former reliance on 2-EH. Western European consumption of oxo chemicals is forecast to grow at an average annual rate of 2.0% during 2008–2013. Japanese consumption is forecast to experience 0.9% average annual growth during 2008–2013. Other Asian consumption, excluding Japan, is expected to grow at 5.0% annually during the same period; China, India and Taiwan are the main growth markets in this region. Middle Eastern consumption of oxo chemicals is forecast to grow significantly at an average annual rate of 4.8% during 2008–2013, albeit from a small base, largely as a result of increased n-butanol demand for n-butyl acrylate by late 2010.

(For the complete marketing research report on OXO CHEMICALS, visit this report’s home page or see p. 682.7000 A of the Chemical Economics Handbook.)

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CEH Marketing Research Report Abstract
POLYAMIDE RESINS (NONNYLON TYPES)
By Elvira O. Camara Greiner with Thomas Kälin and Takashi Kumamoto

While the generic name polyamide is shared with nylons, the more well-known materials, nonnylon polyamides are unique in their raw materials, manufacturing processes, properties and applications. Only the presence of the amide linkage (–CONH–) in their structural backbones relates these two polymer groups. The nonnylons are composed of dimer acid–based (DAB) resins and epichlorohydrin copolymers.

The DAB polyamides are condensation products of the so-called dimer acids and homologs of either ethylenediamine (aliphatic diamines) for nonreactive polyamides or diethylenetriamine (higher ethyleneamines) for reactive polyamides. The nonreactive DAB polyamides are usually solid, higher-molecular-weight materials, while the reactive group is usually liquid, lower-molecular-weight resins.

Dimer acid–based polyamide resins are either reactive or nonreactive (i.e., they lack amine functionality). Reactive polyamides are utilized primarily as curing agents for epoxy resins used in surface coatings and adhesives. Nonreactive polyamides are used predominantly in hot-melt adhesives and printing inks.

World consumption of DAB polyamide resins will increase at an average annual rate of 2.0–2.5% during 2008–2013. Most of that growth will come from Asia Pacific. The economic crisis of 2008 and 2009 (by midyear) hit the DAB polyamide resins industry hard and consumption contracted significantly in the developed regions. A contraction in consumption of DAB resins for most applications was observed in 2008 and is expected in 2009. Industry sources believe economic recovery may only begin in 2010 followed by higher growth rates during 2011–2013 when markets may try to regain some lost volume.

Consumption of polyamide-epichlorohydrin resins, used primarily for wet-strength applications by the paper industry, is growing in the United States, Western Europe and China. Increased use of facial and kitchen tissues and better wet-strength performance are key factors behind expected average annual growth rates of 2.0–2.5% in the next five years. China will lead this growth on an average percentage basis; however, the United States and Western Europe will still dominate consumption on a volume basis.

(For the complete marketing research report on POLYAMIDE RESINS [NONNYLON TYPES], visit
this report’s home page or see p. 580.1000 A of the Chemical Economics Handbook.)

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CEH Marketing Research Report Abstract
SODIUM CARBONATE
By Stefan Schlag with Chiyo Funada

Sodium carbonate is a white crystalline solid that is also known as disodium carbonate or soda ash. It is a member of the chlor-alkali chemical family and competes with caustic soda as a source of alkali (sodium oxide) in many processes. About 70% of world soda ash production is derived from synthetic processes and 30% is recovered from natural trona deposits and surface brines. Commercial soda ash is highly purified and is sold in various grades that differ primarily in bulk density.

Developed countries have higher per capita consumption of soda ash but lower growth rates than developing countries. However, the end-use patterns are basically the same for both. Glass production accounts for half of global soda ash consumption, with commercial and residential construction driving flat glass demand, whereas consumer packaging trends, recycling and competition from other packaging materials dictate use in container glass. The second-largest market for soda ash is the chemicals sector, where it is used as an alkali source in numerous chemical processes and as a feedstock in the production of sodium chemicals. The third major use for soda ash is in formulated detergents and cleaners as a builder.

The following pie chart shows world consumption of soda ash:

(For the complete marketing research report on SODIUM CARBONATE visit this report’s home page or see p. 770.4000 A of the Chemical Economics Handbook.)

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CEH Marketing Research Report Abstract
SULFUR
By Bala Suresh

Sulfur is one of the chemical industry’s most important raw materials. It is used principally as the derivative (sulfuric acid) in many chemical and industrial processes and is particularly important in the manufacture of phosphate fertilizers, the single largest end use for sulfur. Sulfur’s great importance to industrial economies and its relative ease of transportation have made it a commodity of major international interest. Unlike other chemicals in the mineral industry, sulfur is not produced intentionally as a primary product. It is derived as a by-product from operations such as petroleum refining, tar sands recovery, heavy oil and natural gas processing, and from coking and metallurgical plants.

The global sulfur market experienced unprecedented turbulence in pricing in 2008. Prices climbed from about $150–200 per ton in fall 2007 to about $750–800 per ton in July 2008, followed by a record decline to about $45–50 by the end of 2008. Supply shortfall coupled with increasing demand from the fertilizer and industrial sectors, along with reducing inventory levels, contributed to price hikes. A reduction in Chinese imports and the effect of the global economy’s steep fall, thereby reducing demand for phosphate fertilizer, resulted in reduced trade causing a collapse in pricing by the end of 2008. Currently, the sulfur market has moved away from a deficit position to an emerging surplus condition.

The following pie chart shows world consumption of sulfur:

Production and consumption of sulfur in China will continue to grow as a result of demand for sulfuric acid for producing fertilizers and chemicals. Imports of crude have almost doubled in the past five years. The processing of high-sulfur-content crude results in large quantities of sulfur. Along with the sulfur going into sulfuric acid production for phosphate fertilizers, China has also been importing sulfur, primarily from Canada. China has also been investing in desulfurization, sulfur recovery and tail gas treatment processes that depend on both imported and domestic technology. Sulfur recovery plants have doubled in number since 2000.

Sulfur was once produced primarily from native sulfur and Frasch deposits or recovered as sulfuric acid from electively mined pyrite deposits. The development of the natural gas industry and the oil refining industry has significantly changed the nature of the sulfur industry. Natural gas resources often contain a significant level of sulfur-containing gases that must be removed before the gas can be used commercially. Lately, the amount of world sulfur produced as a by-product of natural gas production has exceeded the volume produced electively from native sulfur and Frasch deposits and recovered as sulfuric acid from pyrites. In 2009, over half of the expected increase of 7–9% in elemental sulfur is to come from the processing of sour natural gas. In addition, environmental regulations governing the desulfurization of transportation fuels have also resulted in significant quantities of sulfur being recovered from refinery operations and will continue to lead to increased recovery of by-product sulfur.

For many years, sulfuric acid recovered at nonferrous smelters has been the main concern. Of greater significance today is the recovery of elemental sulfur from crude oil refineries as the sulfur content of crudes has increased and as regulations on the sulfur content of oil and gasoline products have become increasingly stringent. Ultra-low-sulfur diesel fuel will soon be the major form sold. In the United States, by 2010, a switch will have been made of most diesel fuel from low-sulfur diesel (LSD) to ULSD (diesel fuel that meets the 15 parts per million [ppm] sulfur standards) as a result of the highway diesel fuel sulfur program under the Tier II Refined Product Standards of the Clean Air Act. Currently, it is roughly estimated that about 90% of world sulfur production is by-product and only around 10% is elective.

The Middle East emerged during the 1980s as a significant source of sulfur. Sulfur produced in the Middle East is recovered from petroleum and natural gas. Many projects have been announced in recent years for new production of sulfur. Though there have been delays in construction and commissioning, and the growth in output is not likely to be as strong as projected, the Middle East has been adding significant capacity. The former USSR (primarily Russia and Kazakhstan) has also become a significant source of supply to the international market as sulfur no longer being consumed domestically is being marketed internationally. Gazprom’s subsidiary and Astrakhan account for over 90% of Russian production. Tengizchevroil in Kazakhstan is adding sulfur production capacity in 2009. Western Europe has switched from a net import position of about 2 million metric tons per year to a net export position of almost 2 million metric tons per year. Compensating somewhat for these new export sources has been a sharp decline in exports from Eastern Europe (Poland) where production from native sulfur has become unprofitable due to low world sulfur prices. However, Poland still continues to mine sulfur.

(For the complete marketing research report on SULFUR, visit this report’s home page or see p. 780.0000 A of the Chemical Economics Handbook.)

PEP Review Abstract
AMMONIA FROM NATURAL GAS BY THE KBR PURIFIER PROCESS
By Victor Y. Wan

While the overall process layout of some well-proven ammonia processes has remained unchanged for the last decade, their performance has improved as a result of improvements in areas such as synthesis gas generation and purification, the energy efficiency and reliability of carbon dioxide removal systems, synthesis loop equipment designs and the switch from electrically driven compression to the use of waste heat generated steam-driven centrifugal compressors. In addition, new plants tend to be larger, with improved economies of scale.

The KBR Purifier Process features a firing reduction in the primary reforming furnace and a cryogenic system that removes inert components from the raw ammonia synthesis gas. The cryogenic purifier removes excess nitrogen introduced by the excess of air fed to the secondary reformer, all methane and most of the argon. The technology has been in operation in more than fifteen commercial ammonia plants.

This review evaluates an SRIC design based on the KBR Purifier Ammonia Process incorporating design features reflecting the above-mentioned process improvements. The front-end synthesis gas preparation is through natural gas reforming with excess air, CO shift, aMDEA carbon dioxide removal, methanation, drying and cryogenic purification. The ammonia synthesis loop features a horizontal cross-flow magnetite converter, steam-driven compressors and a unitized chiller.

Our work suggests that at a base case capacity of 1,448 million lb/yr (2,000 metric tons per day), the total fixed capital is $595.4 million. The overall natural gas energy consumption (for feed and fuel) is 13,332 Btu/lb NH₃ on an LHV basis. The base case product value (net production cost plus 25%/yr return on investment) is 31.4¢/lb when natural gas is priced at 889¢/MMBtu.

(For the complete July 2009 Review 2009-11 on AMMONIA FROM NATURAL GAS BY THE KBR PURIFIER PROCESS, visit this report’s home page.)

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PEP Review Abstract
POLYPHENYLENE SULFIDE (PPS)
By R.J. Chang

Demand for polyphenylene sulfide (PPS) has been growing rapidly in recent years due to a unique combination of its physical properties and favorable performance/cost ratio compared with other high performance thermoplastics. Major producers have also increased their capacities significantly. Meanwhile, there have been numerous new process patents issued or applied for since PEP’s last report published in 1990. This review provides a brief update of industry status including the development of new end-use applications which underline some market drivers for the recently growing demand. A recent production process patented by Ticona was selected for this process economics study, and the results are presented.

(For the complete August 2009 Review 2009-6 on POLYPHENYLENE SULFIDE [PPS], visit
this report’s home page.)

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