The main application for methyl ethyl ketone (MEK) is as a low-boiling solvent for nitrocellulose, acrylic and vinyl surface coatings. Over half of global MEK demand is derived from the paints and coatings industry. Its advantage is that low viscosity solutions can be obtained, having a high solids content, without affecting the film properties. These lacquers are used in the automotive, electrical goods and furniture industries.
MEK can also be used in rubber-based industrial cements and printing inks. Its fast evaporation rate makes it popular for rubber-based industrial cements, low-temperature bonding agents and as an azeotropic separation solvent for printing inks. It is also a component of the solvent system used in producing magnetic tape.
MEK is also a solvent required for the polymerisation processing of polystyrene, acrylonitrile-butadiene-styrene (ABS), and styrene-butadiene rubber (SBR). A derivative of MEK, methyl ethyl ketone peroxide, is used as a catalyst to initiate the polymerisation of polyester resins used in fibre glass reinforced plastics.
MEK is a mature product with most of its applications only growing slowly. Regionally, the European and US markets are flat. Growth is concentrated in Asia with the Chinese market being the main driver. SRI Consulting forecasts worldwide MEK consumption to grow at an average rate of 3.5%/year during the 2005 – 2010 period to reach 1.3m tonnes in 2010.
In the US, MEK has been in decline as a solvent for coating applications since the late 1980s when the Environmental Protection Agency (EPA) first proposed to limit volatile organic compounds (VOCs) and classified MEK as a hazardous air pollutant (HAP). However, at the end of 2005, the EPA removed MEK from the HAP list contained in section 112 of the Clean Air Act.
This action was in response to a petition submitted by the American Chemistry Council on behalf of MEK producers and users to delete MEK from the HAP list. While this is good news for producers and users, it is unlikely that short term benefits will follow. Product reformulation is expensive for any manufacturer and benefits will only be realised when new product opportunities are identified.
The strongest growth market for MEK is in adhesives, chemical intermediates and printing inks. According to ICIS Chemical Business Americas (ICBA), this segment is growing at 2-3%/year in the US.
MEK is used in solvent blends for urethane lacquers that are used to coat magnetic tapes but consumption in this application has been declining. MEK functions as a dewaxing agent during the refining of lubricating oils. More efficient engines today produce fewer emissions, lowering MEK demand in dewaxing operations.
The US markets have also been struggling with a gloomy housing sector and a downturn in automobile production. Overall, ICBA predicts an aggregate growth rate in the US of 0.7%/year up to 2009. Domestic demand will increase from 194,000 tonnes in 2005 to 200,000 tonnes in 2009.
The closure of Shell’s 130,000 tonnes/year MEK plant in Norco, Louisiana, in September 2004, has shifted the US from being a net exporter to a net importer of MEK.
The loss of Shell’s capacity will be balanced by the strong growth in capacity in Asia, particularly China. Since 2000, a number of new plants have come on-stream in China, according to China Chemical Reporter (CCR). It is projected that MEK demand will grow at an average rate of 6-7%/year to reach about 300,000-320,000 tonnes/year in 2007. If all planned projects are completed on schedule, MEK capacity could reach 350,000 tonnes/year in 2007, estimates CCR.
Meanwhile, China has imposed preliminary anti-dumping duties on imports of MEK from Japan, Singapore and Taiwan. The immediate impact was a fall of MEK imports into China.
(Updated: September 2007. Sources: ICB Chemical Profile, 3 September 2007; ICBA Chemical Profile, 4 September 2006).
Methyl ethyl ketone
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Process Technologies
The main commercial route to MEK is the dehydrogenation of secondary butanol. Some companies employ sulphuric acid hydration of n-butene to make the secondary butanol.
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