The traditional method of manufacturing benzene from the distillation of light oils produced during the manufacture of coke has been overtaken by a number of processes. The main sources now are from catalytic reforming or steam cracking of liquid petroleum feedstocks, as well as the hydrodealkylation (HDA) of toluene and toluene disproportionation (TDP).
In Europe, benzene is obtained primarily from pyrolysis gasoline coproduced in the steam cracking of naphtha, gasoil or condensates to make olefins. The amount of aromatics produced can be increased by employing heavier feedstocks.
In the US, catalytic reforming is a major source of benzene. Naphtha is mixed with hydrogen and fed into a reactor containing a catalyst and operating at 425-530oC and 7-35 bar. An aromatic-rich fraction is separated from the reformate.
In both routes, the benzene needs to be recovered from the aromatics stream. Methods include solvent extraction, extractive or azeotropic distillation, solid adsorption using molecular sieves and crystallisation.
A growing source of benzene is by the selective disproportionation of toluene where benzene is coproduced in the manufacture of a paraxylene-rich xylenes stream. The gasoline pool is also an increasing source as stricter gasoline regulations limit the benzene/aromatics content of gasoline.
The final supply of benzene comes from the hydrodealkylation of toluene using either catalytic or thermal processes. HDA plants are usually used to maintain the balance of benzene supply when all other sources of benzene can not meet demand.
A new process called Cyclar that converts butanes and propanes into aromatics has been developed by BP and UOP. So far, only one plant in Saudi Arabia has been built using the new technology.
Benzene
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Benzene
Uses and Outlook
Benzene is the largest-volume aromatic used to produce a number of petrochemical intermediates such as ethylbenzene for styrene production, cumene for phenol and acetone, cyclohexane and nitrobenzene.
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