ACROLEINE (AC)
The benchmark deals with the energy-efficiency of the production of pure acroleine (AC) by oxidation of propene (propylene). The system boundary covers the AC production unit itself, the workup and the offgas treatment. Plants that produce the feed component propene are not included.
ACRYLIC ACID
Acrylic Acid can be used as the raw material for the production of acrylic esters and for polyacrylates like superabsorbent polymers (SAPs). There are several chemical routes to produce AA, but the most common one is via the partial oxidation of propylene by a two step process in which propylene is first oxidized to acrolein and then further oxidized to AA. Each reaction step usually takes place over a separate catalyst and at different operating conditions. The reaction steps are highly exothermic.
BISPHENOL-A
Bisphenol A (BPA) is the main raw material for manufacturing polycarbonate (PC) and epoxy resins. The benchmark covers the synthesis of BPA from acetone and excess phenol via a catalyzed reaction and the separation and purification to a purified crystalline product. The molten BPA may be delivered to the customers or may be further processed in a solidification section to form shapes such as spherical prills, flakes and pellets. The potential recovery and recycling of useful feed and product streams is also incorporated in this benchmark.
BUTANEDIOL
The butanediol benchmark deals with the propylene oxide (PO) hydroformylation route with PO and syngas as feedstock.
CAPROLACTAM
Most caprolactam units in the world use either phenol or cyclohexane as the raw material. The system boundary of the caprolactam benchmark includes all units required to produce caprolactam from cyclohexanone.
DIMETHYL TEREPHTHALATE (DMT)
The DMT benchmark covers manufacturing plants producing dimethyl terephthalate from p-xylene by successive oxidation and esterification with methanol. The benchmark includes the purification section: light-ends and heavy-ends removal and purification by crystallization.
EDC/VCM (ETHYLENE DICHLORIDE / VINYL CHLORIDE)
The benchmark involves the production of vinyl chloride monomer (VCM) via thermal cracking of 1,2-dichloroethane (EDC) and the production of EDC from ethylene by chlorination and/or oxychlorination. The benchmark focuses on the balanced EDC/VCM process, and also accommodates plants producing EDC only or VCM from import EDC.
EO/EG
The system boundary of the ethylene oxide / ethylene glycol (EO/EG) process comprises all units required to manufacture high purity ethylene oxide and/or high purity ethylene glycols from ethylene and pure oxygen. Part of the ethylene raw material is completely combusted providing some of the process energy requirement. This is accounted for in evaluating the energy efficiency. A correction method applies for the final EO-EG product ratio in order to arrive at a fair comparison between participants.
MDI
The methyl diphenyl diisocyanate (MDI) benchmark starts with aniline and formaldehyde as the feed. The system includes three steps: i) production of methylene dianiline (MDA), ii) production of phosgene from CO and Cl2, and iii) the phosgenation of MDA to crude MDI. The MDI precursor aniline is covered by a dedicated PDC benchmark. The purification of crude MDI to final MDI products (monomeric MDI, polymeric MDI, modified MDI) is excluded from the system boundary.
METHYLMERCAPTANE (MC)
The system boundary of this benchmark includes the production of the intermediate product hydrogen sulfide, the downstream methylmercaptane (MC) reaction itself as well as the workup of the reaction mixture.
METHYLAMINES
This energy benchmark covers the production of mono-, di, and trimethylamine from ammonia and methanol. Because of custom-made plant layouts, corrections are made to account for differences between participants, especially with respect to the product mix.
MIBK (METHYL ISOBUTYL KETONE)
The benchmark deals with the production of Methyl Isobutyl Ketone (MIBK) from acetone by aldol condensation via diacetone alcohol and mesityl oxide in a single- or multiple-step process.
MTBE
The benchmark covers Methyl Tertiary Butyl Ether (MTBE) plants with mixed C4 feedstocks (Raffinate-1). Products are MTBE and an isobutylene-free mixed C4 stream. MTBE plants using pure isobutylene as a feedstock (e.g. isobutylene byproduct from the PO/TBA process) are not included. For this specific MTBE process see the PO/TBA benchmark.
NITROBENZENE / ANILINE
This energy benchmark comprises of two steps: i) production of nitrobenzene from benzene and nitric acid, ii) production of aniline by hydrogenation of nitrobenzene. Possible import or export of nitrobenzene has been taken into account. World aniline production is almost completely applied for MDI production, for which a dedicated PDC benchmark exists.
OXO ALCOHOLS
This benchmark covers the production of (plasticizer range) higher branched alcohols from C5 to C14 (branched) olefins via the High Pressure Cobalt technology.
PHENOL / ACETON (CUMENE ROUTE)
This energy benchmark covers the co-production of phenol and acetone via the well-known cumene-route. Cumene is oxidized by enriched air/oxygen to form cumene hydroperoxide, which is subsequently cleaved into phenol and acetone in the presence of an acid catalyst. Phenol and acetone are then purified to meet market specifications. Because of the custom-made plant layouts, corrections are made to account for the differences between participants.
PO/SM (INCLUDING UPSTREAM EB-UNIT)
This benchmark deals deals with the co-production of propylene oxide and styrene monomer via hydroperoxidation of ethylbenzene The ethylbenzene hydroperoxide then, is used to epoxidize propylene to propylene oxide. The resulting byproduct from this epoxidation step (methylbenzyl alcohol) is dehydrated in a subsequent step to form the co-product styrene monomer (SM). The study includes energy-benchmarking of the upstream ethylbenzene (EB) production unit, which benchmark results are reported separately.
PO/TBA
The PO/TBA process consists of the following process steps: Isobutane is oxidized to t-butylhydroperoxide, which is used for the epoxidation of propylene to propylene oxide (PO). The resulting byproduct t-butyl alcohol is dehydrated and used for the manufacture of MTBE. PO can be used for manufacturing propylene glycols and propylene glycol ethers. The benchmark comprises all the above-mentioned process steps, and treats them as separate blocks.
PROPYLENE GLYCOL ETHERS
The benchmark deals with the production of propylene glycol ethers from propylene oxide and alcohols (methanol, ethanol, propanol, …).
TOLUENE OXIDATION (TOLOX)
This is a benchmark of toluene oxidation plants, which have benzaldehyde, benzoic acid and phenol as products.