Petrochemicals are products made from oil or gas and are traded internationally, with various types and uses. Petrochemical plants use different methods and configurations, but all require specialized equipment and highly trained personnel. They are often located near oil and gas refineries, but proximity to raw materials does not always guarantee maximum production.
Petrochemicals are products obtained from hydrocarbon-based raw materials such as oil or gas, which are referred to as raw materials. The trade in petrochemicals is international and involves large sums of money. A petrochemical plant is a facility where products are made to supply this industry.
There are numerous types of petrochemicals and petrochemical end products. Some have consumer uses and some are primarily for industrial use. The primary petrochemical industry produces substances such as methanol, ethylene, toluene and propylene directly from raw materials. Intermediate and derivative petrochemicals are generally produced when the primary petrochemicals are converted into a more complicated form. Such products include vinyl acetate for paint, vinyl chloride for PVC, and styrene for rubber and plastics.
Since stocks of feed and the resulting petrochemicals vary, there are numerous methods of production. A petrochemical ethylene plant is likely to use a method known as catalytic cracking, which uses high pressure and high temperatures to break down natural gas by repeated compression and distillation. In a petrochemical plant producing methanol, a reforming process is likely to be used. This method uses high temperature, medium pressure steam and a catalyst to produce the product.
Different factors, such as raw materials, end products, method of production and location, determine numerous types and configurations of petrochemical plants. There are, however, characteristics of petrochemical plants that tend to be standard. For example, nearly all petrochemical plants need extensive piping networks. Most use rotary kilns and equipment. While sizes vary, every petrochemical plant needs an expanse of land to operate on.
The petrochemical industry tends to be technology intensive. Most petrochemical plants, therefore, will require specialized equipment, sophisticated engineering and highly trained personnel. This means that regardless of the feedstock or resulting products, a petrochemical plant is normally very expensive and requires a significant amount of capital.
Petrochemical plants are located in different countries of the world. Gas and oil are the most common commodities, because they are usually less expensive than other commodities, are widely available, and can be processed more efficiently. For this reason, petrochemical companies often build their plants near oil and gas refineries. This significantly reduces operational costs, such as transportation, associated with receiving feed stocks.
Being closest to the source of the necessary raw materials doesn’t always translate into maximum production. The many differences in petrochemical plants result in varying capacities. Even when multiple petrochemical plants are owned by the same company, there is usually a difference in the output of each.
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