Acrylonitrile (ACN) Uses and Market Data

25 February 2009 10:54  [Source: Chemical Report]

Acrylonitrile (ACN) is used mainly as a monomer or comonomer in the production of synthetic fibres, plastics and elastomers.

 

The largest outlet is in the manufacture of acrylic fibres, which are soft and light with warm tactile feeling similar to wool fibres. Hence they are used in clothing such as sweaters and jumpers, socks and sports wear. Acrylic fibres also have uses in home furnishings and bedding such as carpets, upholstery, cushions and blankets.

 

Acrylic fibres contain at least 85% of the acrylonitrile monomer. Those fibres which contain 35-85% ACN are modacrylic fibres. Since modacrylic fibres can be copolymerised with vinyl chloride or vinylidene chloride, they are flame retardant and used in curtains and wigs.

 

Globally, growth in acrylic fibres has been slow at 1-2%/year with the main growth in Asia. There has also been a shift in production from Europe and North America to China with the US no longer producing acrylic fibre. More recently, acrylic fibre markets globally have been in decline, partly due to demand destruction caused by high ACN prices as a result of high feedstock costs. In western Europe, acrylic fibre output has been falling at 6-7%/year.

 

The main growth sector for ACN is the acrylonitrile-butadiene-styrene (ABS)/styrene-acrylonitrile (SAN) market. ABS and SAN resins are positioned between the commodity and engineering polymers leading to competition with other polymers such as polyvinyl chloride (PVC) and polystyrene (PS).

 

A growing outlet for ABS is the electronics industry where it is used in business machines, computers, radios, televisions and telephone handsets while an important market is the automobile industry. SAN is used in appliances, packaging, household goods and automotive applications.

 

Most markets for ABS are mature, but it continues to find new applications. Long-term global growth is predicted by industry observers at around 4-5%/year with the strongest growth in China.

 

Nitrile rubbers, made by the copolymerisation of ACN with butadiene, have good resistance to abrasion, heat aging, lubricating oils and gasoline. With applications chiefly in the automotive sector, nitrile rubbers are expected to see long-term steady growth at 3.5%/year.

 

Acrylonitrile is used to produce adiponitrile, which is an intermediate in the manufacture of nylon 6,6 polymers. The nylon fibres market is mature with little growth but nylon engineering polymers are performing much better.

 

The catalytic hydrolysis of ACN produces acrylamide, which can make a variety of homopolymers and copolymers. These polymers are used as flocculants in water and waste treatment, mobility control agents in crude oil recovery, retention aids in paper manufacture, and in froth flotation processes. Acrylamide markets are expected to grow fairly strongly.

 

Polyacrylonitrile (PAN) is the precursor for carbon fibre in high strength applications ranging from aircraft parts to sporting equipment. PAN-based carbon fibre is a low volume speciality material due its relatively high cost to produce.

 

Slow market growth for ACN

 

Global demand for ACN is only expected to grow by 1-2%/year, with strongest demand in Asia pulled by the growth in ABS. Regionally, China will lead the growth while little growth or even a decline will be seen in Europe and the US.

 

Overcapacity had been a problem for ACN markets but they are now much better balanced due to plant closures brought about by poor demand and surging feedstock costs. In general, plant closures have exceeded capacity additions with ACN supply becoming tight to balanced. There has also been a shift in capacity from North America to Asia.

 

According to UK-based consultant Tecnon OrbiChem, global capacity in 2008 was just over 6.2m tonnes/year. European capacity was 1.25m tonnes/year in 2008 with no changes expected to 2015.

 

While a number of projects have been studied, the only major project underway is a 200,000 tonnes/year plant being built in Map Ta Phut, Thailand by Asahi Kasei and Thailand’s PTT Chemical. Scheduled for commissioning in late 2010, this plant is based on Asahi’s propane process. INEOS will also expand its Green Lake, Texas, plant from 460,000 tonnes/year to 545,000 tonnes/year in 2009.

 

In the US, domestic ACN demand has been declining as its acrylic fibres industry shut down due to expansions in Asia. However, small growth of 0.5%/year is expected to return in the 2008-2012 period with domestic demand increasing from 585,000 tonnes in 2008 to 599,000 tonnes in 2012, according to ICB.

 

In the US, the largest derivative is adiponitrile, which accounts for 36% of demand and used exclusively in the production of an intermediate, hexamethylenediamine, to make nylon 6,6 fibres and resins. Consumption of nylon 6,6 had been growing at about 0.5%/year but in 2008 it declined with the economy.

 

ABS/SAN resins account for another 34% of ACN consumption in the US. With these resins used primarily in durable goods, demand is sensitive to economic conditions. In addition, many ABS/SAN markets are well penetrated and so future growth is expected to be flat.

 

The third largest derivative in the US is acrylamide, accounting for 15% of ACN demand. Most acrylamide is converted to polyacrylamides which are used as flocculants and coagulants in industrial processes and water treatment. This sector has performed well and is expected to show growth of 2.5%/year.

 

ACN exports have accounted for a substantial amount of US production but have been hit by the addition of new overseas capacity and high raw material costs leading to demand destruction. Exports in 2008 declined by 35% to 554,000 tonnes, according to data from the US International Trade Commission.

 

(Updated: February 2009. Sources: ICB Chemical Profiles, 2 February 2009 and 18 August 2008)

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