The 1990's saw big changes in the ethylbenzene industry with the widespread
introduction of zeolite catalysts. These catalysts had significant advantages
over the AlCl3 catalysts then in use. The zeolites mitigated environmental
and corrosion issues while providing operational and yield advantages. In
a business that is typically highly competitive, the cost advantages proved
compelling.
More recently, as diminishing returns have set in, process improvements have
become more incremental. These have concentrated on yield improvements and
efforts to reduce energy requirements. Smaller these improvements may be,
but when you're running a billion pound per year plant, saving even one-tenth
of a cent per pound is worth a million dollars per year.
This review updates our cost estimates for a world-class plant (1.15 billion
lb/yr) using a liquid phase zeolite-catalyzed process for the alkylation of
benzene to produce ethylbenzene. We also look at some of the catalyst and
process improvements that the major licensors have made.
