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CEH Marketing Research Report

PHENOL

By
Elvira O. Camara Greiner

CEH Marketing Research Reports provide comprehensive analysis, historical data and
forecasts pertaining to the international competitive market environment for chemical
products. Detailed supply and demand data are developed for the United States,
Western Europe and Japan with the cooperation of chemical producers and consumers
worldwide.
Updated information may be available from the following CEH Program services:
z CEH Online—The full text retrieval and update database. Updated monthly.
z CEH CD-ROM—The entire contents of the CEH on one CD-ROM and including CEH
Online updates. Issued quarterly.
z Manual of Current Indicators (MCI)—Updates of statistical data derived from
published sources. Issued semiannually.
z The Economic Environment of the Chemical Industry (EECI)—Economic
indicators that impact the chemical industry; issued quarterly.
z CEH Inquiry Service—SRI Consulting researchers are available to answer your
questions.
U.S.A.—Telephone: 650/859-3900 Fax: 650/859-2182
Zürich—Telephone: 411/283-6333 Fax: 411/283-6330
Tokyo—Telephone: 813/5251-1741 Fax: 813/5251-1754

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TABLE OF CONTENTS
SUMMARY.................................................................................................................................................. 4

INTRODUCTION ........................................................................................................................................ 8

MANUFACTURING PROCESSES............................................................................................................. 9
SYNTHETIC PROCESSES ..................................................................................................................... 9
Cumene Peroxidation............................................................................................................................ 9
Toluene Oxidation .............................................................................................................................. 10
NATURAL RECOVERY ....................................................................................................................... 11
OTHER PROCESSES ............................................................................................................................ 11
Benzene Sulfonation ........................................................................................................................... 12
Chlorobenzene Process ....................................................................................................................... 13
Raschig Process .................................................................................................................................. 14
Benzene via Cyclohexene ................................................................................................................... 14
Direct Oxidation of Benzene .............................................................................................................. 15
Direct Catalytic Conversion of Benzene............................................................................................. 16

SUPPLY AND DEMAND BY REGION ................................................................................................... 16


UNITED STATES .................................................................................................................................. 17
Producing Companies ......................................................................................................................... 17
Salient Statistics.................................................................................................................................. 20
Production........................................................................................................................................... 20
Consumption....................................................................................................................................... 22
Bisphenol A .................................................................................................................................... 25
PF Resins ........................................................................................................................................ 26
Caprolactam .................................................................................................................................... 28
Aniline .............................................................................................Error! Bookmark not defined.
2,6-Xylenol ..................................................................................................................................... 31
Adipic Acid..................................................................................................................................... 31
Salicylic Acid...................................................................................Error! Bookmark not defined.
Alkylphenols................................................................................................................................... 32
p-Nonylphenol ............................................................................................................................ 32
p-Dodecylphenol......................................................................................................................... 33
Other ........................................................................................................................................... 34
Other ............................................................................................................................................... 35
Aryl phosphates .......................................................................................................................... 36
o-Cresol....................................................................................................................................... 36
2,4-D ........................................................................................................................................... 36
Pentachlorophenol....................................................................................................................... 37
Cyclohexanol/cyclohexanone ..................................................................................................... 37
Miscellaneous.............................................................................................................................. 37
Price .................................................................................................................................................... 38
Trade ................................................................................................................................................... 40
CANADA................................................................................................................................................ 42
Salient Statistics.................................................................................................................................. 42
MEXICO................................................................................................................................................. 43
Producing Companies ......................................................................................................................... 43
Salient Statistics.................................................................................................................................. 43

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Consumption....................................................................................................................................... 44
SOUTH AND CENTRAL AMERICA ................................................................................................... 45
Producing Companies ......................................................................................................................... 45
Salient Statistics.................................................................................................................................. 45
Consumption....................................................................................................................................... 46
WESTERN EUROPE ............................................................................................................................. 48
Producing Companies ......................................................................................................................... 48
Salient Statistics.................................................................................................................................. 49
Consumption....................................................................................................................................... 50
Price .................................................................................................................................................... 51
CENTRAL AND EASTERN EUROPE ................................................................................................. 53
Producing Companies ......................................................................................................................... 53
Salient Statistics.................................................................................................................................. 54
Consumption....................................................................................................................................... 55
JAPAN .................................................................................................................................................... 55
Producing Companies ......................................................................................................................... 55
Salient Statistics.................................................................................................................................. 56
Consumption....................................................................................................................................... 56
Price .................................................................................................................................................... 58
OTHER ASIA ....................................................................................................................................... 59
Producing Companies ......................................................................................................................... 59
Salient Statistics.................................................................................................................................. 60
Consumption....................................................................................................................................... 61
OTHER REGIONS ................................................................................................................................. 61
Producing Companies ......................................................................................................................... 61
Salient Statistics.................................................................................................................................. 62
Consumption....................................................................................................................................... 62

BIBLIOGRAPHY....................................................................................................................................... 63

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SUMMARY

The following table presents world supply/demand for phenol in 2004:

World Supply/Demand for Phenol—2004


(thousands of metric tons)
Annual Operating
Capacity Rate
(year-end) Production (percent) Imports Exports Consumption

North America
Canada 0 0 -- 162 -- 162
Mexico (42) 0 -- 20 -- 20
United States 2,993 2,650 93a 3 515 2,126
South and Central America 165 140 85 46b -- 186
Western Europe 2,463 2,300 93 1,120c 1,253c 2,167
Central and Eastern Europe 499 332 66 –46b -- 286
Africa 44 40 91 4 30 14
Middle East 0 0 -- 34 -- 34
Japan 974 966 99 1 87 880
Other Asia
China 537 370 69 281 3 648
India 86 80 93 70 5 145
Korea, Republic of 130 121 93 97 7 211
Singapore 250 240 96 15 15 240
Taiwan 540 420 78 22 72 370
Otherd 0 0 -- 249 10 239
Oceania 22 16 73 3 2 17

Total 8,681 7,675 90%e 2,081 1,999 7,745

a. Operating rate is based on an effective capacity of 2,834 thousand metric tons.

b. Datum is reported as net imports.

c. Includes intra-Western European trade.

d. Includes Indonesia, Malaysia, Pakistan, the Philippines, Thailand, Vietnam and the Democratic People’s
Republic of Korea.

e. Operating rate is based on an effective capacity of 8,522 thousand metric tons.

SOURCE: CEH estimates.

Global production of phenol was nearly 7.7 million metric tons in 2004, valued at approximately $7

billion. Global capacity utilization rose to 90% in 2004 from 83% in 2001 because of increased demand

and tighter supply. Phenol prices reached record highs in the fourth quarter of 2004 as a result of rising

feedstock costs and robust demand.

*4* phenol CEH DRAFT—2 May 17, 2005-EG


Bisphenol A (BPA) accounted for 40% of global phenol consumption in 2004, followed by phenol-

formaldehyde (PF) resins at 29%. BPA and PF resins are produced in all regions; production of BPA is

more prevalent in developed economies. Other applications for phenol include caprolactam, alkylphenols,

aniline and adipic acid. Phenol consumption for caprolactam and, to a lesser degree, alkylphenols is

limited to mainly the United States and Western Europe. The following table presents world consumption

of phenol by region and end use in 2004:

World Consumption of Phenol by Region and End Use—2004


(thousands of metric tons)
PF
Bisphenol A Resins Caprolactam Alkylphenols Othera Total

North America
Canada 0 159 0 2 1 162
Mexico 0 12 0 4 4 20
United States 850 650 305 104 217 2,126
South and Central America 20 108 0 6 52 186
Western Europe 928 532 279 100 328 2,167
Central and Eastern Europe 60 110 52 21 43 286
Japan 493 180 0 -- 207 880
Other Asiab 745 555 --c 49 504 1,853
Other Regionsd 10 39 0 0 17 65

Total 3,106 2,345 636 286 1,373 7,745

a. Includes aniline, adipic acid, 2,6-xylenol and other applications. Data may include some phenol consumed for
caprolactam and alkylphenols.

b. Includes China, India, Indonesia, the Republic of Korea, Taiwan, Thailand, Malaysia, Vietnam, the
Democratic People’s Republic of Korea, Singapore, Pakistan and the Philippines.

c. Included in Other.

d. Includes Africa, Middle East and Oceania.

SOURCE: CEH estimates.

Demand for BPA, PF resins and caprolactam are greatly influenced by general economic conditions. As a

result, demand for phenol largely follows the patterns of the leading world economies. The following

table presents world consumption of phenol in 2004 and estimates for 2009 by end use:

*5* phenol CEH DRAFT—2 May 17, 2005-EG


World Consumption of Phenol by End Use
(thousands of metric tons)
Average Annual
Percent of Percent of Growth Rate,
Consumption, Consumption, 2004-2009
2004 2004 2009 2009 (percent)

Bisphenol A 3,106 40 4,258 45 6.5


PF Resins 2,345 30 2,687 29 2.8
Caprolactam 636 8 653 7 0.5
Alkylphenols 286 4 308 3 1.5
Other 1,373 18 1,546 16 2.4

Total 7,745 100% 9,452 100% 4.1%

SOURCE: CEH estimates.

The following table presents world consumption of phenol by region in 2004 and estimates for 2009:

World Consumption of Phenol by Region


(thousands of metric tons)
Average Annual
Percent of Percent of Growth Rate,
Consumption, Consumption, 2004-2009
2004 2004 2009 2009 (percent)

North America
Canada 162 2.1 188 2.0 3.0
Mexico 20 0.3 24 0.3 3.7
United States 2,126 27.4 2,416 25.6 2.6
South and Central America 186 2.4 220 2.3 3.4
Western Europe 2,167 28.0 2,571 27.2 3.5
Central and Eastern Europe 286 3.7 323 3.4 2.5
Japan 880 11.4 957 10.1 1.7
Other Asia 1,853 23.9 2,663 28.2 7.5
Other Regions 65 0.8 90 1.0 6.7

Total 7,745 100% 9,452 100% 4.1%

SOURCE: CEH estimates.

Consumption of phenol for BPA will experience high growth rates in most regions, as both increased

demand and capacity for BPA will result in strong demand for phenol. As a result, BPA producers are the

most influential global consumers of phenol. Consumption of phenol for PF resins, on the other hand,

shows more regional variation. In the United States, Western Europe and Japan, phenol consumption for

PF resins is forecast to grow at 1-2% annually between 2004 and 2009. This is in contrast to developing

markets, such as Central and Eastern Europe and South and Central America (where consumption in both

*6* phenol CEH DRAFT—2 May 17, 2005-EG


regions is forecasted to grow at 3.6% annually), and Southeast Asia where consumption is expected to

grow at 5.0%.

After experiencing strong demand in 1999 and most of 2000, phenol markets declined or remained

stagnant in most regions in 2001 as a result of the economic slowdown. Lower margins, depressed

demand and significant capacity additions in 2000 and 2001 forced many phenol producers to cut

production in 2001 (and some to even exit the market). There was a global oversupply of phenol in 2002

and 2003. The situation changed dramatically in 2004 with the help of an improving global economy.

Once again demand for phenol increased substantially, driven by phenolic resins (used largely in

construction applications) and BPA. High operating rates, tight supply (due to raw material shortage) and

increased demand also drove phenol prices to historical highs. Margins were also improved despite rising

raw material costs. The weak dollar and increased demand for phenol in East Asia also provided good

export opportunities for U.S. producers.

The market in 2005 will most likely continue to fair well, but as East Asia continues to bring on

additional capacity to meet demand growth in the region, North American export opportunites will

decline. This will translate into lower operating rates in North America.

Although overall economic performance will continue to be the best indicator of future demand for

phenol, other issues that may affect the phenol market during the next five years are as follows:

z Continued high demand for bisphenol A, mainly for polycarbonate resins

z Possible stricter environmental regulations concerning formaldehyde emissions from PF resins

The following table presents the largest producers of phenol by capacity:

Major Global Producers of Phenol—2005


Annual Nameplate Capacity
as of February 2005
(thousands of Percent of
metric tons) World Capacity

INEOS Phenol 1,620 19

*7* phenol CEH DRAFT—2 May 17, 2005-EG


Sunoco 927 11
Mitsui 640 7
Shell 535 6
Polimeri Europa 480 6
Formosa 400 5
Ertisa 360 4
Georgia Gulf 300 3
Dow 295 3

Total 5,557 64%

SOURCE: CEH estimates.

With the exception of INEOS Phenol and Mitsui none of the top phenol producers currently operate

plants in more than one region, as regional suppliers generally meet demand. The regional capacity

concentration thus reflects variations in local demand requirements. INEOS Phenol is the largest global

producer; with two plants in Europe and one in the United States. Sunoco operates two plants in the

United States while Mitsui Chemicals has plants in Japan and Singapore.

INTRODUCTION

Phenol (carbolic acid; hydroxybenzene; C6H5OH) is a white, crystalline solid at room temperature. Most

phenol is consumed molten as a clear, colorless liquid. It is both the simplest hydroxybenzene and the

most commercially important. Phenol was first isolated from coal tars in the mid-1800s. Currently, nearly

all world production of phenol is via cumene peroxidation, with acetone as a coproduct. Its main use is as

a chemical intermediate in the manufacture of bisphenol A, phenol-formaldehyde resins, caprolactam,

alkylphenols, aniline and 2,6-xylenol.

Some of the chemicals discussed in this report are typically referred to by abbreviations, rather than their

chemical names. The most frequently used abbreviations are listed below.

BPA Bisphenol A

PF Resins Phenol-formaldehyde resins

MF Resins Melamine-formaldehyde resins

ABS Acrylonitrile-butadiene-styrene resins

*8* phenol CEH DRAFT—2 May 17, 2005-EG


PC Polycarbonate resins

MDI Methylenebis(4-phenyl isocyanate)

OSB Oriented strandboard

MANUFACTURING PROCESSES

Phenol can be produced from several processes. However, cumene peroxidation is the most common

process, since it currently offers the most cost-effective process economics. Although other synthetic

processes have been developed, most future phenol plants will be cumene-based.

Until the advent of synthetic phenol just before World War I, natural phenol recovered from coal tar and

petroleum streams was the only available source. Since that time, synthetic phenol has increased in

importance to the extent that it now accounts for nearly all global production, with more than 90% of

global capacity based on cumene peroxidation.

SYNTHETIC PROCESSES

CUMENE PEROXIDATION

Cumene is prepared by alkylating benzene with chemical- or refinery-grade propylene at about 230°C and

a pressure of 500 pounds per square inch gauge (psig) using various catalysts, predominantly zeolites,

solid phosphoric acid or aluminum chloride. Purified cumene is then oxidized with air to cumene

hydroperoxide at about 110-115°C and 80 psig in an alkali environment. The oxidation product is

separated and the bottoms, composed of cumene hydroperoxide in approximately 85% concentration, are

mixed with a small amount of acetone and sulfuric acid and maintained at about 77°C and atmospheric

pressure while the hydroperoxide splits into phenol and acetone. The reaction mixture is separated into

phenol, acetone and small amounts of alpha-methylstyrene and other by-products. The alpha-

methylstyrene is typically hydrogenated to cumene and recycled, although some is recovered for

monomer uses.

*9* phenol CEH DRAFT—2 May 17, 2005-EG


CH 3
C H
+ CH2 CHCH3 CH2

benzene propylene cumene

mol wt: 78.1 42.1 120.2

CH 3 CH3
C H C O OH
+ O2 CH 3
CH3

cumene
cumene hydroperoxide
mol wt: 120.2 152.2

CH 3
C O OH OH O
CH3 + CH3 C CH3

cumene
hydroperoxide phenol acetone

mol wt: 152.2 94.1 58.1

The industry average yield of phenol from the above process is about 91% of theoretical based on

benzene (0.91 unit of benzene per unit of phenol produced) and 95% based on cumene (1.35 units of

cumene per unit of phenol produced). These factors include the hydrogenation and recycle of alpha-

methylstyrene; yields decline by 3.5% when alpha-methylstyrene is recovered. Coproduct acetone is

obtained in the ratio of 0.60-0.62 unit acetone to 1.0 unit phenol.

TOLUENE OXIDATION

Toluene is oxidized with air to benzoic acid at about 160°C and 60 psig in the presence of a cobalt acetate

catalyst. Benzoic acid is separated, melted, mixed with a small amount of magnesium-promoted cupric

benzoate and converted to phenol by an oxidative decarboxylation reaction with air at about 240°C and

atmospheric pressure. Phenol is recovered by distillation. The major reactions are summarized as follows:

*10* phenol CEH DRAFT—2 May 17, 2005-EG


CH 3 COOH
+ 3 O2 + 2 H2O
2 2

toluene benzoic acid

mol wt: 92.1 122.1

OH
COOH
+ O2 2 + 2 CO2
2

benzoic acid phenol

mol wt: 122.1 94.1

The yield of phenol from toluene is believed to be only about 68% of theoretical, corresponding to 1.44

units of toluene consumed per unit of phenol produced.

NATURAL RECOVERY

Most natural phenol originates from petroleum caustic wash streams consisting primarily of cresols; only

minor amounts are derived from coal tar refining operations.

Phenols are generated as coproducts during catalytic cracking of petroleum. The effluent stream of the

cracker is washed with sodium hydroxide, primarily to remove mercaptans and other organic sulfur

compounds. The caustic wash operation simultaneously extracts phenols and cresols as sodium salts.

Similarly, the refining of tars and off-gases from coke ovens involves a caustic wash of the lighter

fractions in which phenols, cresols and xylenols transfer to the aqueous phase as soluble sodium salts.

The natural phenol producers process the caustic wash streams to regenerate and recover phenol, cresols,

xylenols and mixtures known as cresylic acids, either for sale or for captive use.

OTHER PROCESSES

Three processes for synthetic phenol production are no longer used in the United States, Western Europe

or Japan. These include benzene sulfonation, the chlorobenzene process and the Raschig process. All

*11* phenol CEH DRAFT—2 May 17, 2005-EG


have limited use in other regions and will probably be phased out eventually in favor of newer

technology.

BENZENE SULFONATION

Benzenesulfonic acid is prepared by reacting benzene with oleum or concentrated sulfuric acid at

temperatures of up to approximately 150°C. The benzenesulfonic acid is reacted with sodium sulfite and

the sodium benzenesulfonate (containing a small amount of sodium sulfate) is separated. The sodium

benzenesulfonate is fused with sodium hydroxide at about 315°C to yield sodium phenolate. Sodium

phenolate solution is acidified with sulfur dioxide and a small amount of sulfuric acid. The crude phenol,

which separates as an upper layer over a solution of sodium sulfite (and a small amount of sodium

sulfate), is separated and purified by distillation. The process may be summarized as follows:

SO3H SO3Na
+ 2 Na 2SO3 + SO2 + H 2O + Na2SO 3
2 2

benzenesulfonic sodium
acid benzenesulfonate

mol wt: 158.2 180.2

SO3Na ONa

+ 2 NaOH + Na2SO3 + H 2O

sodium sodium
benzenesulfonate phenolate

mol wt: 180.2 116.1

ONa OH
H2SO 4
2 + SO2 + H 2O 2 + Na2SO3

sodium
phenolate phenol

mol wt: 116.1 94.1

*12* phenol CEH DRAFT—2 May 17, 2005-EG


The yield of phenol is about 88% of theoretical or 1.06 units of phenol per unit of benzene consumed.

The ratio of phenol produced to coproduct sodium sulfite produced is about 1:1.7.

CHLOROBENZENE PROCESS

The chlorobenzene process involves three steps. Benzene is chlorinated at 38-60°C in the presence of a

ferric chloride catalyst to form monochlorobenzene:

Cl

+ Cl2 + HCl

benzene chlorobenzene

mol wt: 78.1 112.6

Chlorobenzene and aqueous caustic soda are introduced, along with small quantities of anticorrosion

agents, emulsifiers and a catalyst, into a reactor in which hydrolysis to sodium phenolate takes place at

4,000 pounds pressure and 400°C. The impure sodium phenolate is reacted with hydrochloric acid to

obtain phenol, which is decanted and distilled under vacuum. These reactions are summarized as follows:

SO3Na ONa

+ 2 NaOH + Na2SO3 + H 2O

sodium sodium
benzenesulfonate phenolate

mol wt: 180.2 116.1

ONa OH
H2SO 4
2 + SO2 + H 2O 2 + Na2SO3

sodium
phenolate phenol

mol wt: 116.1 94.1

The yield of phenol by this process is about 82% of theoretical based on benzene and 95% based on

chlorobenzene.

*13* phenol CEH DRAFT—2 May 17, 2005-EG


RASCHIG PROCESS

The Raschig process produces phenol from benzene in two catalytic vapor-phase stages. Benzene is

oxychlorinated to chlorobenzene with hydrochloric acid and air in the presence of iron and copper

chloride catalysts at approximately 200-260°C and atmospheric pressure. Hydrolysis of chlorobenzene at

about 480°C over a suitable catalyst produces phenol and hydrochloric acid:
Cl

+ HCl + 1/2 O2 + H 2O

benzene chlorobenzene

mol wt: 78.1 112.6

Cl OH
+ H2O + HCI

chlorobenzene phenol

mol wt: 112.6 94.1

The yield of phenol by the Raschig process is believed to be about 89% of theoretical based on benzene.

BENZENE VIA CYCLOHEXENE

Mitsui Chemicals patented a new process that uses benzene as the feedstock. Benzene is partially

hydrogenated to cyclohexene (with a ruthenium-zinc catalyst), reacted with water to form cyclohexanol

or oxidized to cyclohexanone, followed by dehydrogenation of the oxygenated compound, yielding

phenol.

catalyst
+ 2 H2
H2O

benzene cyclohexene

*14* phenol CEH DRAFT—2 May 17, 2005-EG


OH OH
+
H
+ H2 O
catalyst catalyst

cyclohexene cyclohexanol phenol

O OH

O2
+ 3 H2 + 2 H2
catalyst catalyst

cyclohexene cyclohexanone phenol

Cyclohexane, formed as a coproduct in the benzene hydrogenation reaction, is dehydrogenated to

benzene, which is recycled and used in the initial hydrogenation step. Hydrogen produced in the

cyclohexanol/cyclohexanone dehydrogenation reaction and the cyclohexane dehydrogenation reaction is

sufficient to supply the initial hydrogenation step. The cyclohexanol/cyclohexanone intermediate also

may be used in the production of alternate products, including caprolactam and adipic acid.

DIRECT OXIDATION OF BENZENE

Mitsui Chemicals has also developed a process for converting benzene to phenol with nitric acid as the

oxidizing agent:

OH

+ 2 HNO3 + 2 NO 2 + H 2O

benzene phenol

A small amount of nitrobenzene is formed as a by-product. Nitrogen dioxide and water may be converted

to nitric acid for recycling.

*15* phenol CEH DRAFT—2 May 17, 2005-EG


DIRECT CATALYTIC CONVERSION OF BENZENE

Solutia has developed a one-step process that produces phenol directly from benzene and nitrous oxide.

The major advantages of this process include the use of waste nitrous oxide from Solutia’s adipic acid

production, a high yield and elimination of cumene (as an intermediate) and acetone (as a coproduct).

Solutia operated a benzene-to-phenol pilot plant for two to three years at Pensacola, Florida in support of

its planned 136 thousand metric ton plant, originally due for completion in 1999. JLM Industries was to

market approximately one half of the output. However, faced with an oversupplied phenol market and

after postponing the project twice, Solutia and JLM Industries terminated their agreement to build the

plant in mid-2001.

SUPPLY AND DEMAND BY REGION

Global end-use markets for phenol are similar in all regions. The following table presents applications for

the major derivatives of phenol; variations in regional applications are discussed under each region:

Applications of Phenol
Derivative Main Products Main Markets Remarks

Bisphenol A PC resins (automotive Automotive, OEM, opti- Consumption is dependent on OEM and
lighting systems, instrument cal media, construction automotive production, construction,
panel clusters, front and rear (residential and nonresi- remodeling activity and discretionary
bumpers, exterior car pan- dential), remodeling and income and personal spending. PC com-
els, CDs, CD-ROMs, computers. petes with glass and acrylic resins in
DVDs, windows and doors, glazing/sheet and automotive applications
signs and displays, appli- and ABS in appliances/power tools.
ances/power tools and com-
puter housings).

Epoxy resins (surface coat- Automotive OEM, con- Consumption is dependent on OEM and
ings, rigid printed circuit tainers, industrial struc- automotive production, construction,
boards, adhesives). tures (maintenance and remodeling activity. Epoxy resins com-
new construction) and pete with polyurethanes and modified
computers. acrylics in adhesive applications.

PF Resins Wood adhesives for oriented Construction (residential Competes with MDI in OSB. Consump-
strandboard (OSB), hard- and nonresidential), re- tion is dependent on construction, remod-
board and plywood. modeling and furniture. eling activity and furniture production.
Decorative laminates for Construction (residential Competes with MF resins, mineral-filled
cabinets, furniture, paneling and nonresidential), re- acrylic sheet and low-pressure polyester
and kitchen and bathroom modeling and furniture. laminates.
countertops. Industrial lami-
nates for gears, bearings,
valves and printed circuits.

*16* phenol CEH DRAFT—2 May 17, 2005-EG


Foundry materials. Automotive Competes with silicate and other inor-
(transmission and ganic no-bake systems.
crankcase cores) and
aerospace.
Structural and acoustic in- Construction (residential PF resins act as adhesives to bind the
sulation (glass fiber, mineral and nonresidential) and insulation materials. Waste fibers are
wool, waste fiber). automotive. used in roof and side sheeting in cars.
Molding compounds. Automotive (engine and Competes with polybutylene and polyeth-
transmission assemblies ylene terephthalate in appliances and
and brake components), housewares and with polyester bulk
appliances (iron handles), molding compounds in electrical applica-
housewares (cookware tions.
handles, toaster end pan-
els) and electrical (outlet
boxes, sockets).

Caprolactam Nylon 6 fibers (carpet and Construction (residential Consumption is dependent on construc-
rug yarns), resins (auto- and nonresidential), re- tion and remodeling activity and OEM
motive and truck parts modeling, OEM and and automobile production. Nylon 6 fi-
including rear-end license automotive. bers for carpets and rugs compete with
panels, louvers, mirror resilient flooring, laminates and tile.
housings and wheel covers
and fan blades) and films
(food packaging).

SOURCE: CEH estimates.

UNITED STATES

PRODUCING COMPANIES

The following table presents U.S. producers of phenol:

*17* phenol CEH DRAFT—2 May 17, 2005-EG


U.S. Producers of Phenol
Annual Capacity
as of January 1, 2005
(thousands of
Company and Plant Location metric tons) Process Remarks

Dakota Gasification Company


Beulah, ND 15 Natural recovery from coal All merchant sales.
gasification

Dow Chemical U.S.A.


Oyster Creek, TX 295 Cumene peroxidation Purchased cumene. Some captive consumption for
bisphenol A and salicylic acid. Merchant sales account
for approximately 40%.

Georgia Gulf Corporation


Pasadena, TX 73 Cumene peroxidation Captive cumene. All merchant sales. Plant was
temporarily idled in 2002.
Plaquemine, LA 227 Cumene peroxidation Captive cumene. All merchant sales.

INEOS Phenol Inc.


Theodore, AL 490a Cumene peroxidation Purchased cumene. All merchant sales.

JLM Chemicals, Inc.


Blue Island, IL 45 Cumene peroxidation Captive cumene. All merchant sales.

Merisol USA LLCb


Houston, TX 12 Natural recovery from petroleum All captive consumption for xylenols and cresols.
and coal tars

Mount Vernon Phenol Plant Partnershipc


Mount Vernon, IN 340 Cumene peroxidation Purchased cumene. Mostly captive consumption by part
owner GE for bisphenol A, 2,6-xylenol, nonylphenol and
phenolic resins.

Noveon Inc.
Kalama, WA 34 Toluene oxidation Purchased toluene. Some captive consumption for
alkylphenols.

Shell Chemical Company


Deer Park, TX 535 Cumene peroxidation Captive cumene. All merchant sales.

*18* phenol CEH DRAFT—2 May 17, 2005-EG


Sunoco, Inc.
Ironton, OH 427d Cumene peroxidation Captive and purchased cumene. Some captive
consumption for bisphenol A. Merchant sales account for
approximately 50%.
Philadelphia, PA 500 Cumene peroxidation Captive cumene. All merchant sales, mainly to
Honeywell for caprolactam.

Total 2,993e

a. INEOS Phenol’s annual capacity as of February 2005 is 540 thousand metric tons.

b. Owned 50% by Merichem Company and 50% by Sasol Limited, South Africa.

c. Partnership was established in 1987, with GE holding 49%; CITGO Petroleum Corp., 49%; and JLM Industries, 2%. Plant is operated by GE Plastics.

d. Namplate capacity is 427 thousand metric tons. A temporarily idled unit of 159 thousand metric tons brings effective capacity to 268 thousand metric tons.

e. Namplate capacity. Effective capacity is 2,834 (Sunoco has a 159 thousand metric tons-per-year unit temporarily idled).

SOURCE: CEH estimates.

*19* phenol CEH DRAFT—2 May 17, 2005-EG


SALIENT STATISTICS

The following table presents U.S. salient statistics for phenol:

U.S. Supply/Demand for Phenol


(thousands of metric tons)
Annual
Nameplate Operating
Capacity Rate Actual
(year-end) (percent) Production Imports Exports Consumption

1987 1,597 95 1,519 4 84 1,453

1992 1,879 91 1,701 9 149 1,559


1993 1,891 91 1,730 19 134 1,639
1994 1,891 99 1,873 29 140 1,781

1995 2,006 95 1,899 42 141 1,870


1996 2,024 94 1,905 106 135 1,921
1997 2,067 94 1,936 138 132 1,965
1998 2,160 94 2,033 153 176 2,009
1999 2,280 96 2,197 183 176 2,090

2000 2,937 87 2,548 54 265 2,195


2001 2,937 82 2,401 14 288 2,015
2002 2,943 80 2,350 27 332 2,025
2003 2,943 83 2,449 6 507 1,935
2004 2,993 93a 2,650 3 515 2,126

a. Operating rate is based on an effective capacity of 2,834 thousand metric tons since Sunoco
temporarily idled a 159 thousand metric tons-per-year unit in 2003.

SOURCE: CEH estimates.

PRODUCTION

The following table presents U.S. production and sales of phenol:

*20* phenol CEH DRAFT—2 May 17, 2005-EG


U.S. Production and Sales of Phenol
(thousands of metric tons)
Production

Synthetica
Sales
From From Other
Cumene Processes Total Natural Total Synthetic Natural

1960 78 253 331 19 350 173 19


1965 254 278 532 25 557 218 24
1970 529 245 774 21 795 336 13
1975 703 75 778 14 792 420
1980 1,133 18 1,151 14 1,165 588

1985 1,256 20 1,276 12 1,288 649


1986 1,378 23 1,401 12 1,413 700
1987 1,476 27 1,503 16 1,519 695
1988 1,573 27 1,600 15 1,615 715
1989 1,575 29 1,604 15 1,619 654

1990 1,561 29 1,590 15 1,605 682


1991 1,579 27 1,606 25 1,631 889
1992 1,647 29 1,676 25 1,701 938
1993 1,676 29 1,705 25 1,730 959
1994 1,816 30 1,846 27 1,873 709

1995 1,841 31 1,872 27 1,899 --


1996 1,847 31 1,878 27 1,905 --
1997 1,878 31 1,909 27 1,936 --
1998 1,975 31 2,006 27 2,033 --
1999 2,138 31 2,169 28 2,197 --

2000 2,502 31 2,533 15 2,548 --


2001 2,350 31 2,381 20 2,401 --
2002 2,304 31 2,335 15 2,350 --
2003 2,403 31 2,434 15 2,449 --
2004 2,604 31 2,635 15 2,650 --

See MANUAL OF CURRENT INDICATORS for additional information.

a. Reported data for phenol produced from noncumene-based processes were overstated by the source for
1977, 1978, 1980-1989 and 1991-1993. The data in this table have been adjusted to represent actual
conditions more accurately. The data reported by the source were as follows (thousands of metric tons):

*21* phenol CEH DRAFT—2 May 17, 2005-EG


From All Other
Cumene Phenol

1977 967 93
1978 869 347

1980 1,104 61
1981 1,119 42
1982 918 69
1983 932 265
1984 1,237 73

1985 1,212 76
1986 1,343 70
1987 1,421 99
1988 1,299 317
1989 1,406 320

1990 1,593 12
1991 1,119 na
1992 1,636 127
1993 1,447 97

The data for All Other Phenol are believed to include natural and noncumene synthetic phenol, as
reported by the source. Reported production in 1989 is believed to be overstated.

SOURCES: (A) Synthetic Organic Chemicals, U.S. Production and Sales, U.S. International Trade
Commission (data for TOTAL SYNTHETIC PRODUCTION and SALES except for
1971; data for NATURAL PRODUCTION for 1960-1974; data for SYNTHETIC
FROM CUMENE for 1975-1977 and 1979; data for TOTAL PRODUCTION for 1975-
1991; data in footnote a).

(B) Preliminary Report on U.S. Production of Selected Synthetic Organic Chemicals, U.S.
International Trade Commission (data for NATURAL PRODUCTION for 1976-1978).

(C) CEH estimates (all other data).

Cumene peroxidation has been the primary source of phenol since 1967. Cumene-based phenol accounted

for 98% of total U.S. production in 2004, up from 22% in 1960.

CONSUMPTION

The following table presents U.S. consumption of phenol:

*22* phenol CEH DRAFT—2 May 17, 2005-EG


U.S. Consumption of Phenol
(thousands of metric tons)
Average Annual
Percent of Growth Rate,
Consumption 2004-2009
2004 in 2004 2009 (percent)

Bisphenol A 850 42 1,060 4.5


PF Resins 650 27 684 1.0
Caprolactam 305 15 322 1.1
Alkylphenols
p-Nonylphenol 71 3 71 0
p-Dodecylphenol 33 2 31 -1.2
2,6-Xylenol 82 4 100 4.0
Adipic Acid 20 <1 20 0
Other 115 6 128 2.2

Total 2,126 100% 2,416 2.6%

SOURCE: CEH estimates.

The following table presents historical U.S. consumption of phenol:

Historical U. S. Consumption of Phenol


(thousands of metric tons)
Bisphenol Aa PF Resinsb Caprolactamc 2,6-Xylenold Nonylphenole Anilinef
1965 38 252 73 -- 14 0
1970 79 327 108 4 18 0
1975 114 361 131 20 19 0
1980 207 439 166 36 35 0

1985 317 474 225 54 43 30


1986 335 476 231 39 49 57
1987 402 503 245 43 49 66
1988 433 519 249 48 47 73
1989 441 528 254 49 50 73

1990 477 477 265 50 53 54


1991 502 458 254 48 55 68
1992 486 476 261 50 56 66
1993 524 494 275 51 59 59
1994 588 540 290 54 62 66

1995 657 542 299 57 62 68


1996 689 556 300 61 62 68
1997 715 560 305 65 63 67
1998 747 564 305 68 64 68
1999 825 564 298 75 66 67

2000 940 575 290 80 67 61


2001 830 535 278 73 67 60
2002 809 542 292 80 69 60
2003 798 530 288 79 71 0
2004 850 650 305 82 71 0

*23* phenol CEH DRAFT—2 May 17, 2005-EG


Historical U. S. Consumption of Phenol (continued)
(thousands of metric tons)
Adipic Salicylic
Dodecylphenolg Acidh Acidi Otherj Total
1965 11 17 8 100 513
1970 14 21 14 110 695
1975 14 23 11 90 783
1980 16 19 14 97 1,029

1985 17 9 10 100 1,279


1986 18 9 11 105 1,330
1987 21 9 9 106 1,453
1988 23 9 10 105 1,516
1989 25 9 9 108 1,546

1990 26 9 9 116 1,536


1991 26 9 9 117 1,546
1992 26 9 9 120 1,559
1993 27 14 10 126 1,639
1994 27 14 10 130 1,781

1995 28 16 11 130 1,870


1996 28 16 11 130 1,921
1997 31 16 11 132 1,965
1998 31 16 11 135 2,009
1999 32 16 11 136 2,090

2000 33 19 11 119 2,195


2001 33 19 10 110 2,015
2002 33 19 8 113 2,025
2003 33 20 0 116 1,935
2004 33 20 0 115 2,126

a. Assumes that 0.86 unit of phenol is consumed per unit of bisphenol A produced during 1987-2000;
0.88 unit of phenol was consumed in prior years.

b. Assumes that, on the average, 0.73 unit of phenol is consumed per unit of PF resin produced.

c. Assumes that 0.90 unit of phenol is consumed per unit of caprolactam produced during 1987-2000;
0.92 unit of phenol was consumed in prior years.

d. Assumes that 0.80-0.82 unit of phenol is consumed per unit of 2,6-xylenol produced.

e. Assumes that 0.46 unit of phenol is consumed per unit of p-nonylphenol produced.

f. Assumes that 1.02 units of phenol are consumed per unit of aniline produced. Sunoco idled its aniline
plant at Ironton, Ohio in December 2002.

g. Assumes that 0.38 unit of phenol is consumed per unit of p-dodecylphenol produced.

h. Assumes that 0.72 unit of phenol is consumed per unit of adipic acid produced.

i. Assumes that 0.80 unit of phenol is consumed per unit of salicylic acid produced. Rhodia shut down
the sole U.S. acetylsalicylic acid plant in February 2003.

j. Category incorporates changes in inventory.

SOURCE: CEH estimates.

*24* phenol CEH DRAFT—2 May 17, 2005-EG


Bisphenol A

Bisphenol A (BPA) is produced by reacting phenol and acetone in the presence of an acid catalyst.

Estimated U.S. production of 988 thousand metric tons of BPA in 2004 required 850 thousand metric tons

of phenol. Yields based on phenol consumption are typically 96% of theoretical, requiring 0.85-0.87 unit

of phenol per unit of BPA produced.

General Electric, Resolution Performance Products, Bayer, Dow and Sunoco produce BPA in the United

States. With the exception of Bayer and Resolution Performance Products, all producers have captive

sources of phenol and acetone, and, with the exception of Sunoco, all have captive uses for BPA.

The following table presents U.S. consumption of bisphenol A:

U.S. Consumption of Bisphenol A—2004


(percent)

Polycarbonate Resins 71
Epoxy Resins 23
Flame Retardants 4
Other 2

Total 100%

SOURCE: CEH estimates.

Automotive applications accounted for 20% of the total U.S. consumption of polycarbonate (PC) resins in

2004—PC resins are used in place of metal and glass in automotive components. Glazing and sheet uses,

such as architectural, security and transportation, also accounted for 20% of PC resin consumption.

Optical media, including audio compact discs (CDs), CD-ROMs, recordable CDs and digital versatile

disks (DVDs) accounted for 20% of demand in 2004. PC resin consumption for this sector increased at

more than 40% per year during 1988-2000. Other important markets for PC resins include appliances and

business and electronics applications. In addition, PC resins have a variety of smaller uses including

medical applications, recreational products, safety equipment and packaging applications. Optical discs

are the fastest-growing use for PC resins, with CDs being the largest-volume sector in the category and

recordable CDs and DVDs driving the market.

*25* phenol CEH DRAFT—2 May 17, 2005-EG


Surface coatings account for approximately 53% of all U.S. epoxy resin consumption. Most epoxy resins

consumed in coatings are made from bisphenol A and epichlorohydrin. Other uses for epoxy resins

include fiber-reinforced laminates and composites, bonding and adhesives, flooring and paving, casting

and molding resins and various specialty applications.

BPA is used in the production of tetrabromobisphenol A (TBBA), which is used to impart flame

resistance to epoxy resins used in printed circuit boards, polycarbonates, ABS and unsaturated polyester

resins. Other small volume applications for BPA include unsaturated polyester resins, polysulfone resins,

polyetherimides and polyarylates.

For additional information, see the CEH Bisphenol A product review and the CEH Polycarbonate Resins

and Epoxy Resins marketing research reports.

PF Resins

The manufacture of phenol-formaldehyde (PF) resins is a relatively simple operation. Phenol,

formaldehyde and a catalyst are charged into a reactor and initially heated to 60-65°C to initiate reaction.

The reaction is terminated at the desired product properties by cooling. While continuous processes have

been developed, batch production is practiced to capitalize on the flexibility of the facilities; the same

equipment is often used to produce resins with varying formulations and molecular weights over a short

period of time. On the average, about 0.73 unit of phenol is required per unit of PF resin produced (100%

solids), with resins for wood products requiring less phenol and industrial resins requiring more phenol

per unit of resin.

The largest U.S. producers of PF resins are Georgia-Pacific, Borden, Dynea and Durez. With the

exception of Durez, all of these producers have captive formaldehyde but none has captive phenol.

The following table presents U.S. consumption of phenol-formaldehyde resins:

*26* phenol CEH DRAFT—2 May 17, 2005-EG


U.S. Consumption of Phenol-Formaldehyde Resins—2004
(percent)

Wood Adhesives
Fibrous and Granulated Wood 35
Plywood 21
Insulation 14
Laminates 8
Foundry Materials 7
Molding Compounds 5
Other 10

Total 100%

SOURCE: CEH estimates.

Oriented strandboard (OSB) accounts for 82% of U.S. PF resin consumption in fibrous and granulated

wood. OSB has been gaining market share at the expense of plywood, primarily because of its low cost,

performance characteristics and the limited availability of plywood because of logging restrictions. OSB

is used in paneling, roofing and flooring. Consumption of phenol in fibrous and granulated wood

applications has increased since OSB production requires 10-20% more PF resins per square foot than

plywood. Demand for PF resins for the production of OSB has been driving the demand for phenol in the

PF resin market. Other fibrous and granulated wood products include hardboard and molded wood.

Hardboard has also replaced plywood in some applications. It is used in furniture, paneling, door skins,

insulation and flooring. PF resins are also used in the small but fast-growing application of laminated

veneer lumber (LVL), an engineered wood composite used in residential and commercial applications.

LVL’s durability and strength allows for its use in manufactured housing, truck and container decking,

scaffold planks, wooden I-beams and floor joists. Increases in LVL production will make up for some of

the decrease in PF resins consumed in plywood production.

PF resins are used to bind glass fiber, mineral wool (rock wool) or shredded waste fibers, such as cotton,

wool or polyester, for structural and acoustical insulation. Glass fiber accounts for over 80% of PF resin

consumption in insulation.

*27* phenol CEH DRAFT—2 May 17, 2005-EG


PF resin–based laminates are used in decorative and industrial applications. Decorative applications

constitute the largest market; end uses include furniture, wall paneling, cabinet faces, tables and

countertops. The fastest growing market is high-pressure flooring laminates. Industrial phenolic laminates

compete primarily with epoxy and silicone products.

Phenolic molding compounds are used for heat-resistant components for household appliances, wiring

devices in the electrical industry and under-the-hood parts in the automotive market. The automotive and

appliance markets are the largest. Durez is the largest U.S. producer of phenolic molding compounds.

Foundries are used for casting metal products. PF resins are used as adhesives to strengthen the core used

for molding to allow hollow casting. HA-International (jointly owned by Borden and Delta-HA) is the

largest player in the U.S. phenolic foundry market; other participants include Georgia-Pacific Resins and

Capital Resin.

Other applications for PF resins include friction materials (clutch facings, disk brake pads, automatic

transmission components), rubber processing additives (in tires, shoe soles and other molded rubber

goods) and abrasives for metal finishing.

For more information, see the CEH Phenolic Resins marketing research report.

Caprolactam

Phenol is catalytically hydrogenated to yield cyclohexanone and cyclohexanol. The choice of catalyst

determines the cyclohexanone-to-cyclohexanol ratio. Cyclohexanone is the main product, with

cyclohexanol usually accounting for less than 5% of the output. Cyclohexanone is then reacted with

hydroxylamine sulfate to produce cyclohexanone oxime. The oxime is reacted initially with sulfuric acid

and then aqueous ammonia to yield caprolactam. The average yield is approximately 92% of theoretical,

requiring 0.90 unit of phenol per unit of caprolactam produced.

*28* phenol CEH DRAFT—2 May 17, 2005-EG


Honeywell is the sole U.S. producer of caprolactam from phenol at its 363 thousand metric ton-per-year

plant in Hopewell, Virginia.

In 2004, approximately 850 thousand metric tons of caprolactam were produced in the United States.

Phenol-based caprolactam accounted for 40% of this market. Honeywell consumes most of its

cyclohexanone captively for the production of caprolactam, but reserves a portion of cyclohexanone for

contract sales. By-product cyclohexanol is sold on the merchant market. (This excludes the product made

in Honeywell’s 5 thousand metric ton-per-year on-purpose cyclohexanol plant. The phenol consumed for

this cyclohexanol production is included in “other” uses of phenol.)

The following table presents U.S. caprolactam production from phenol and phenol consumed in its

production:

U.S. Caprolactam Production and Phenol Consumption


Caprolactam Production
from Phenol Phenol
Consumed
for Caprolactama
Thousands of Percent of (thousands of
Metric Tons Total metric tons)

1965 82 62 73
1970 120 52 108
1975 145 45 131
1980 185 45 166

1985 250 51 225


1986 255 51 231
1987 272 52 245
1988 277 48 249
1989 282 49 254

1990 295 47 265


1991 282 48 254
1992 290 48 261
1993 306 47 275
1994 315 47 290

1995 320 46 299


1996 333 40 300
1997 339 39 305
1998 339 46 305
1999 331 43 298

2000 322 41 290


2001 309 40 278
2002 324 41 292

*29* phenol CEH DRAFT—2 May 17, 2005-EG


2003 320 40 288
2004 339 40 305

a. Approximately 0.90 unit of phenol is consumed per unit of caprolactam


produced.

SOURCE: CEH estimates.

The following table presents U.S. consumption of caprolactam:

U.S. Consumption of Caprolactam—2004


(percent)

Nylon 6 Fibers 71
Nylon 6 Resins and Films 27
Other 2

Total 100%

SOURCE: CEH estimates.

The main market for nylon 6 fibers is in carpet and rug yarns, which account for 75% of U.S.

consumption. The remaining markets are in industrial applications such as tire cord and in apparel items

such as hosiery, lingerie and active wear. This market is driven by construction and remodeling activity.

U.S. demand for nylon 6 resins and films is growing at a faster rate than for nylon 6 fibers. Nylon 6 resins

exhibit high abrasion, chemical and heat resistance and superior tensile strength. The largest market is

automotive and truck parts for under-the-hood components and for some exterior applications, including

rear-view and side mirrors. Nylon 6 resins are also used for industrial machinery parts, power tools,

garden tools, film and extrusion coatings and wire and cable applications. Nylon 6 films are used mainly

for food packaging applications.

Consumption of phenol for caprolactam by Honeywell is expected to grow at an average annual rate of

1.1% during 2004-2009. U.S. consumption of caprolactam is forecast to grow at an average annual rate of

2.0% during 2004-2009.

For additional information, see the CEH Caprolactam marketing research report.

*30* phenol CEH DRAFT—2 May 17, 2005-EG


2,6-Xylenol

Phenol is catalytically methylated in the vapor phase with methanol to form 2,6-xylenol (2,6-

dimethylphenol); small volumes of o-cresol and 2,4,6-trimethylphenol are also produced. Yields are

reportedly 94-96% of theoretical, requiring 0.80-0.82 unit of phenol for each unit of 2,6-xylenol

produced.

General Electric Company (GE) is the largest U.S. producer of synthetic 2,6-xylenol; Schenectady

isolates small amounts of synthetic 2,6-xylenol during o-cresol manufacture from phenol. Nearly all 2,6-

xylenol is consumed in the production of polyphenylene ether (PPE) homopolymer, marketed as

polyphenylene oxide (PPO®) resins. These resins are blended with high-impact polystyrene and sold by

GE under the trademark Noryl®. The largest market for these resins is in automotive applications,

electronics and appliances. They are also used in computer housings, competing with ABS and

polycarbonate. PPO® resins can also be blended with other polymers such as nylon to achieve special

properties. Minor volumes of 2,6-xylenol are used to manufacture 2,6-dimethylaniline (a pesticide

intermediate) and the antioxidant bis(4-hydroxy-3,5-dimethylphenyl)methane.

In the United States, xylenols are also isolated from coal tar fractions and petroleum extracts as mixed

isomers; Merisol USA in Houston, Texas employs this process. However, methylation of phenol is

currently the only economical route to large volumes and high-purity 2,6-xylenol.

U.S. consumption of phenol for 2,6-xylenol is expected to grow at an average annual rate of 4.0%

between 2004 and 2009, reaching 100 thousand metric tons. For additional information on 2,6-xylenol,

see the CEH Polyphenylene Ether Resins/Alloys and Cresols, Xylenols and Cresylic Acid product reviews.

Adipic Acid

Inolex Chemical Company is the sole U.S. producer of adipic acid from phenol at its 20 thousand metric

ton-per-year plant in Hopewell, Virginia. This plant is operated in association with Honeywell’s

*31* phenol CEH DRAFT—2 May 17, 2005-EG


caprolactam facility. Honeywell operates the plant for Inolex. Currently, all other U.S. adipic acid

producers use cyclohexane.

Inolex recovers adipic acid as a by-product in the manufacture of cyclohexanone, an intermediate in the

production of caprolactam from phenol. Yields are reportedly 89% of theoretical, with 0.72 unit of phenol

consumed for each unit of adipic acid produced. Inolex consumes most of its adipic acid captively for

polyurethanes.

For additional information, see the CEH Adipic Acid and Cyclohexane marketing research reports.

Alkylphenols

Phenol is consumed in the production of a variety of alkylphenols. p-Nonylphenol and p-dodecylphenol

are the two most commercially significant alkylphenols made from phenol. Propylene trimer (nonene) or

tetramer (dodecene) is reacted with phenol in the presence of an acid catalyst such as sulfuric acid or

boron trifluoride to produce a mixture of isomers. Yields are typically 93% for p-nonylphenol and 95%

for p-dodecylphenol, requiring 0.46 and 0.38 unit of phenol per unit of p-nonylphenol and p-

dodecylphenol, respectively.

p-Nonylphenol

p-Nonylphenol, the most commercially important alkylphenol, is produced by Dover Chemical,

Crompton Corporation, Huntsman and Schenectady International in the United States. Schenectady is the

largest producer; in mid-2004, the company accounted for nearly 54% of U.S. capacity. The major

applications for p-nonylphenol are in surfactants, antioxidants and lube oil additives.

The largest market for p-nonylphenol is in surfactants, accounting for 75-80% of consumption. p-

Nonylphenol is ethoxylated with ethylene oxide to manufacture p-nonylphenol ethoxylates (NPEs). NPEs

are nonionic surfactants that are used mainly in detergent liquids and powders, as well as personal care

products. Approximately 35% of NPEs are consumed in industrial and commercial cleaning products.

*32* phenol CEH DRAFT—2 May 17, 2005-EG


About 45% of NPEs are used in industrial applications (as emulsifiers, degreasers and wetting agents).

Household cleaning products, mainly laundry detergents, accounted for approximately 20%.

NPEs compete with alcohol ethoxylates (AE) and sulfonated ethoxylates (AES) for the heavy-duty liquid

detergent market. Procter & Gamble and Lever Brothers have replaced NPEs in brand-name laundry

products with AE and AES because they biodegrade faster. NPEs, however, are still used by a major

detergent manufacturer in its industrial and commercial products and have gained market share with the

smaller detergent manufacturers and in private-label brands because of their better detergency and lower

cost. For additional information on NPEs, see the CEH Surfactants, Household Detergents and Their Raw

Materials marketing research report and Nonene (Propylene Trimer) and Tetramer product review.

Phosphite antioxidants decompose hydroperoxides, protect rubber and act as stabilizers for plastics and

elastomers. Phosphites are allowed in indirect food use. They also act as secondary antioxidants to

hindered phenols (such as butylated hydroxytoluene—BHT), which are used as stabilizers in plastics.

Tris-(4-nonylphenyl) phosphite (TNPP) is the largest-volume antioxidant produced from p-nonylphenol,

accounting for 80% of total antioxidant applications. The largest U.S. producer of phosphite antioxidants

is Crompton; other suppliers include Dover Chemical, Arkema and Great Lakes.

Other uses of p-nonylphenol include the manufacture of phenate lube oil additives, tackifier resins and

ethoxylated p-nonylphenol–formaldehyde resins.

p-Dodecylphenol

Chevron Oronite, Infineum U.S.A. (a joint venture of ExxonMobil and Shell) and Schenectady

International produce p-dodecylphenol in the United States. In 2004, U.S. production of p-dodecylphenol

was 86 thousand metric tons, requiring 33 thousand metric tons of phenol.

Over 90% of U.S. demand of p-dodecylphenol is consumed by Chevron Oronite, Infineum and Lubrizol

for the manufacture of detergent-class lubricating oil additives, based primarily on calcium-, magnesium-

and barium phenates. These additives have detergent, antioxidant, lubricity and anticoagulant properties.

*33* phenol CEH DRAFT—2 May 17, 2005-EG


Consumption of these additives has been driven by the use of p-dodecylphenates in gasoline and diesel

motor oils. However, demand for calcium phenate in marine lubricants, the largest market for phenates, is

stagnant and therefore restricting overall growth. Phenates are also used in transportation and mining

equipment oils, industrial equipment and metalworking oils and functional fluids such as transmission and

brake fluids to keep engines sludge-free and to provide corrosion and oxidation protection.

The other major application for p-dodecylphenol is in the production of p-dodecylphenol ethoxylate, used

primarily as an agricultural spray adjuvant. It provides a finer mist and better adhesion of the pesticide to

plant or soil surfaces. Minor amounts of p-dodecylphenol ethoxylate are also used as nonionic surfactants.

Other

U.S. consumption of phenol for other alkylphenols is included in “Other” in the U.S. consumption table.

The following table presents U.S. consumption of phenol for other alkylphenols in 2004:

U.S. Consumption of Phenol for Other Alkylphenols—2004


Thousands of
Metric Tons Producers

p-tert-Octylphenol 14 Schenectady
Cumylphenols 11 Schenectady
p-tert-Butylphenol 8 Schenectady
Di-tert-butylphenols 6 Albemarle, Schenectady
Amylphenols ⎫ Arkema, Schenectady
o-sec-Butylphenol ⎬ 10 Albemarle, Schenectady

Other 3 Albemarle, Schenectady

Total 52

SOURCE: CEH estimates.

z p-tert-Octylphenol is the largest-volume alkylphenol after p-nonylphenol and p-dodecylphenol.

Its major applications include surfactants, PF resins, ink resins, UV stabilizers and polycarbonate

chain termination.

z p-Cumylphenol (PCP) is used as a chain terminator, mainly in PC resins. Other uses include PCP-

formaldehyde resins, PCP-ethylene oxide condensates for nonionic surfactants and as a

*34* phenol CEH DRAFT—2 May 17, 2005-EG


fungicide/bactericide in lubricating oils. Other cumylphenols include 2,4-dicumylphenol, which

finds use in UV stabilizers and antioxidants and as a synthetic intermediate.

z p-tert-Butylphenol is available in technical and polymer grades. Its largest application is in the

production of PF resins, which accounts for over 50% of consumption. The production of oil field

chemicals is its next largest market, followed by agricultural chemicals.

z Di-tert-butylphenols consume approximately 6 thousand metric tons of phenol annually in the

United States. The 2,4- and 2,6- isomers are used mainly as intermediates in the production of

antioxidants and UV stabilizers.

z Other alkylphenols include amylphenols (used in PF resins, germicides and oil field chemicals),

o-sec-butylphenol (used in the production of a stabilizer for styrene monomer) and

isopropylphenols (used in the production of phosphate esters for functional fluids).

Other

Data for “Other” include phenol requirements for other alkylphenols, discussed in the section

immediately preceding this section.

The following table presents U.S. consumption of phenol in other applications:

U.S. Consumption of Phenol in Other Applications


(thousands of metric tons)
Average Annual
Percent of Growth Rate,
Consumption 2004-2009
2004 in 2004 2009 (percent)

Other Alkylphenols 52.0 44 58.8 2.5


Aryl Phosphates 21.0 17 25.0 3.5
o-Cresol 6.0 4 8.0 5.9
2,4-D 4.4 4 4.2 –0.9
Cyclohexanol/Cyclohexanone 4.3 3 5.0 3.1
Pentachlorophenol 2.0 3 2.0 0
Other 25.0 25 25.0 0

Total 114.7 100% 128.0 2.2%

SOURCE: CEH estimates.

*35* phenol CEH DRAFT—2 May 17, 2005-EG


Aryl phosphates

Triaryl and alkyl diaryl phosphate esters are used as flame retardant plasticizers, hydraulic fluids and lube

oil additives. Triaryl phosphate esters, such as isopropylphenyl diphenyl phosphate, tert-butylphenyl

diphenyl phosphate and triphenyl phosphate are used as flame-retardant plasticizers in polyvinyl chloride

resins, cellulose acetate, polyphenylene oxide resins and other polymers. Alkyl diaryl phosphates,

including isodecyldiphenyl phosphate and 2-ethylhexyl diphenyl phosphate, impart flame retardancy and

improved flexibility at low temperatures. Applications include coated fabrics and wall coverings. For

additional information see the CEH Plasticizers marketing research report.

o-Cresol

On-purpose production of o-cresol via methylation of phenol with methanol is practiced by Merisol USA.

General Electric isolates o-cresol as a coproduct with 2,6-xylenol; consumption of phenol by General

Electric for o-cresol is included with 2,6-xylenol. In addition to isolating o-cresol from petroleum and

coal tars, Merisol USA methylates phenol to produce additional volumes of o-cresol, mainly for

consumption in the growing application of epoxy-cresol novolac (ECN) resins. ECNs have better high-

temperature properties and chemical resistance than conventional epoxy resins. They are used in electrical

laminates and encapsulations, moldings and castings and reinforced plastics requiring high chemical

resistance. For additional information on ECNs, see the CEH Epoxy Resins marketing research report.

2,4-D

The herbicide 2,4-D (2,4-dichlorophenoxyacetic acid) is prepared by reacting monochloroacetic acid and

the sodium salt of 2,4-dichlorophenol, a product of phenol chlorination. Dow AgroSciences and Riverdale

Chemical produce 2,4-D and its salts and esters in the United States. Production of 2,4-D and its esters

and salts was 11-13 thousand metric tons in 2004, consuming approximately 4.4 thousand metric tons of

phenol. U.S. consumption of 2,4-D and its esters and salts has declined in recent years because of

environmental concerns about the possible presence of highly toxic by-products and substitution by other

more selective herbicides.

*36* phenol CEH DRAFT—2 May 17, 2005-EG


Pentachlorophenol

Pentachlorophenol (penta), a wood preservative, is produced by chlorination of phenol; Vulcan Materials

is the sole U.S. producer. U.S. production of 5 thousand metric tons in 2004 required approximately 2

thousand metric tons of phenol; approximately 0.37 metric ton of phenol is consumed per metric ton of

pentachlorophenol produced. The largest use for PCP is as a wood preservative for the treatment of utility

poles. Little if any growth is expected for pentachlorophenol through 2009; U.S. consumption has leveled

to 5-5.5 thousand metric tons annually in recent years. There may be some penta substitution for

chromated copper arsenate (CCA) in utility poles since CCA was banned from being used in residential

applications beginning January 2004. CCA use for industrial applications could also be negatively

affected because of this.

Cyclohexanol/cyclohexanone

Honeywell is the sole U.S. producer of cyclohexanone and cyclohexanol from phenol; all other U.S.

producers use cyclohexane. Most production is used captively in the manufacture of caprolactam; the

remainder is sold on the merchant market. In addition to by-product cyclohexanol, Honeywell operates a

5 thousand metric ton-per-year on-purpose cyclohexanol plant. Cyclohexanol is an intermediate for the

production of cyclohexylamine, the insecticide propargite, cyclohexyl esters and other products.

Cyclohexanone is used in the manufacture of caprolactone, as a carrier solvent to coat magnetic media

onto polyester film, as an intermediate for the production of cyclohexylamines and in the formulation of

PVC cements. For additional information, see the CEH Cyclohexanol and Cyclohexanone marketing

research report.

Miscellaneous

Solutia and Dow consume phenol in the manufacture of diphenyl oxide (DPO, phenyl ether, diphenyl

ether). DPO possesses high thermal stability and is a component of synthetic heat transfer fluids that are

used in both liquid- and vapor-phase systems. Solutia’s (Therminol VP-1®) and Dow’s (Dowtherm® A)

*37* phenol CEH DRAFT—2 May 17, 2005-EG


are blends of DPO and biphenyl; these heat transfer fluids are used in a variety of industries such as

chemicals and fiber/nylon manufacture. DPO is also used as a dye carrier in fibers.

Phenolphthalein is made by condensing phenol and phthalic anhydride in the presence of a dehydrating

agent. It is used primarily as a pH indicator and as a cathartic drug in laxatives (e.g., EX-LAX® and Feen-

a-mint®). Sigma-Aldrich Fine Chemicals is the sole U.S. producer of phenolphthalein. Approximately 0.2

thousand metric tons of phenolphthalein are produced annually, requiring 0.2 thousand metric tons of

phenol.

Phenolsulfonic acids are produced by reacting phenol with sulfuric acid. Sloss Industries and DynaChem

produce phenolsulfonic acids in the United States. Picric acid (2,4,6-trinitrophenol) can be manufactured

by the nitration of a mixture of phenolsulfonic acids; it is used mainly in explosives, pharmaceuticals and

dyes. Less than one thousand metric tons of phenol is consumed annually to manufacture phenolsulfonic

acids and derivatives.

Phenol and phenol derivatives (e.g., picric acid) are also used to manufacture various dyes. Azo dyes are

produced by coupling phenol with diazonium salts. Picric acid is used as a starting material for nigrosine

and induline dyes. Dye production consumes 1-2 thousand metric tons of phenol in the United States

annually. For information on azo dyes, see the CEH Dyes marketing research report.

Additionally, phenol is used as a solvent in petroleum refining, to remove impurities in lube stocks by

solvent extraction and for cleaning (e.g., catalytic crackers). Ethyl Corporation reacts polybutene with

formaldehyde and phenol to produce a dispersant lube oil additive.

PRICE

The following table presents U.S. contract prices and unit export values for phenol:

U.S. Contract Price and Unit Export Value for Phenola


(cents per pound)

Contract Price
Unit Export

*38* phenol CEH DRAFT—2 May 17, 2005-EG


1Q 2Q 3Q 4Q Value

1982 -- 28-33 27.5-32 27.5-32 --


1983 27.5-32 27-29 29-32 28-32 --
1984 30-34 38 33-36 33-36 --

1985 31-34 30-34 33-35 30-34 --


1986 26-29 20-25 23-31 20-25 --
1987 20-24 32-37 45-48 33-36 --
1988 33-39 38-44 40-46 43-49 --
1989 46-48 47-53 44-48 39-39.5 --

1990 40-42 35.5-42 34-36 40-42 32


1991 32.5-36 27-30 24-29 27-30 31
1992 27-30.5 25-30 28-32 25-29 31
1993 27-30 30-33 29-34 26-30 27
1994 25-29 29-33 31-36 38-39 26

1995 37-41 37-41 35-39 30-37 32


1996 30-35 31-37 34-39 37-40 27
1997 37-40 37-40 37-40 37-40 34
1998 37-40 35-39 31-36 26-28 31
1999 24-26 24-26 24-26 24-26 24

2000 24-26 32-34 30-31 30-32.5 29


2001 32.5-36.5 28-32 26-30 28-32 27
2002 32-38 32-38 36-40 39-43 29
2003 39-43 46-50 44-47 38-44 35
2004 42-48 50-56 62-68 65-70 49

2005 65-70 65-70 -- -- --

a. Price bases are synthetic, fob, shipping point, freight equalized, nearest
recognized producing point.

SOURCES: (A) World Petrochemicals Price Update, World Petrochemicals


Program, SRI Consulting (data for CONTRACT PRICE for
1982-1996).

(B) CEH estimates (data for CONTRACT PRICE for 1997-


2004).

(C) U.S. Exports, U.S. Department of Commerce, Bureau of the


Census (data for UNIT EXPORT VALUE).

Generally, phenol prices correlate strongly with propylene and benzene prices. Variations in supply and

demand also affect phenol pricing.

By the end of 2001 phenol prices were still relatively low because of weak demand and abundant supply.

In 2002, prices started climbing in response to increased demand, tighter supplies (due to unplanned

outages) and increased raw material costs. By the second quarter of 2003, prices jumped considerably

*39* phenol CEH DRAFT—2 May 17, 2005-EG


because of escalating benzene and propylene feedstock prices. This, along with plant outages, tight

supplies (fueled by a cumene shortage) and strong demand eventually took phenol prices to historical

highs in 2004 and into 2005. Pricing went from quarterly to monthly and we may see phenol follow

benzene prices more closely. Prices will probably start to decrease in the third quarter of 2005 as

supply/demand becomes balanced.

TRADE

The following table presents U.S. trade in phenol:

U.S. Trade in Phenol


(thousands of metric tons)
Importsa Exportsb

1960 neg 22
1965 neg 5
1970 neg 22
1975 11 23
1980 neg 136

1985 27 64
1986 5 85
1987 4 84
1988 15 87
1989 9 100

1990 13 127
1991 10c 103
1992 9 149
1993 19 134
1994 29 140

1995 42 141
1996 106 135
1997 138 132
1998 153 176
1999 183 176

2000 54 265
2001 14 288
2002 27 332
2003 6 507
2004 3 515

See MANUAL OF CURRENT INDICATORS for additional information.

a. Reported under import code number 517.2014 for 1960-1975,


403.4000 for 1976-1979, 402.2000 for 1980-1988 and 2707.60.90.00
and 2907.11.00.00 for 1989-2004.

*40* phenol CEH DRAFT—2 May 17, 2005-EG


b. Reported under export code number 512.0210 for 1960-1977,
517.2014 for 1978-1988 and 2707.60.20.00 and 2907.11.00.00 for
1989-2004. Export code # 2707.60.20.00 represents phenol(s) derived
from the distillation of high-temperature coal tar, in which the weight
of the aromatic constituents (phenols) exceeds that of the nonaromatic
constituents. Export code # 2907.11.00.00 represents synthetic phenol
and its salts.

c. Source reported imports of 5.6 thousand metric tons, which industry


experts believe were understated. Estimated figure is believed to
better represent actual imports.

SOURCES: (A) U.S. Imports, U.S. Department of Commerce, Bureau


of the Census (data for IMPORTS for 1960-1990 and
1992-2004).

(B) CEH estimates (datum for IMPORTS for 1991).

(C) U.S. Exports, U.S. Department of Commerce, Bureau


of the Census (data for EXPORTS).

The United States has historically been a net exporter of phenol. Imports have been relatively small,

except during 1996-1999 when Phenolchemie imported large volumes in preparation for the

commissioning of its plant in Theodore, Alabama during 2000. The following table presents U.S. imports

of phenol by country of origin in 2004:

U.S. Imports of Phenol by Country of Origin—2004


Country of Thousands of Unit Imports Value
Origin Metric Tons Percent (dollars per kilogram)

Germany 2.0 61 0.73


South Africa 1.2 36 0.56
Other 0.1 3 --

Total 3.3 100% 0.77

SOURCE: U.S. Imports, U.S. Department of Commerce, Bureau of the


Census.

The following table presents U.S. exports of phenol by country of destination in 2004:

U.S. Exports of Phenol by Country of Destination—2004


Unit Exports Value
Country of Thousands of (dollars per
Destination Metric Tons Percent kilogram)

Canada 162.0 31 1.04


South Korea 93.6 18 1.10
Thailand 47.7 9 1.05
Netherlands 46.8 9 0.91

*41* phenol CEH DRAFT—2 May 17, 2005-EG


China 28.8 6 1.18
Other 136.5 27 --

Total 515.4 100% 1.08

SOURCE: U.S. Exports, U.S. Department of Commerce, Bureau of the


Census.

CANADA

SALIENT STATISTICS

The following table presents Canadian salient statistics for phenol:

Canadian Supply/Demand for Phenol


(thousands of metric tons)
Actual Consumption
Annual
Capacitya Apparent PF Alkyl-
(year-end) Production Imports Exports Consumption Resins phenols Other

1987 60 53 27 1 79 73 2 3

1992 0 10b 68 neg 78 73 2 3


1993 0 0 91 neg 91 86 2 3
1994 0 0 73 neg 73 70 2 1

1995 0 0 74 neg 74 71 2 1
1996 0 0 98 0 98 92 2 1
1997 0 0 100 0 100 97 2 1
1998 0 0 116 neg 116 110 2 1
1999 0 0 113 neg 113 110 2 1

2000 0 0 105 neg 105 102 2 1


2001 0 0 130 neg 130 127 2 1
2002 0 0 134 neg 134 131 2 1
2003 0 0 149 neg 149 146 2 1
2004 0 0 162 neg 162 159 2 1

2009 0 0 188 neg 188 185 2 1

a. In 1991, Kemtec Petrochemical Corporation closed its 28 thousand metric ton-per-year East Montreal facility. In
1992, Chatterton Petrochemical Corporation closed its 32 thousand metric ton-per-year phenol plant in British
Columbia.

b. Chatterton Petrochemical produced 10 thousand metric tons of phenol in 1992, using the toluene process, before
its plant closed in May 1992.

SOURCES: (A) World Petrochemicals Program, SRI Consulting (data for 1987 and 1992-1993).

(B) CEH estimates (all other data).

*42* phenol CEH DRAFT—2 May 17, 2005-EG


The fastest-growing market for PF resins in Canada is oriented strandboard (OSB). Consumption of

phenol in Canada is expected to grow at an average annual rate of 3% during 2004-2009. Most Canadian

imports of phenol originate in the United States. Imports have increased in the last two years with

Borden’s Edmonton, Alberta phenolic resins plant addition of 100 thousand metric tons.

MEXICO

PRODUCING COMPANIES

The following table presents Mexican producers of phenol:

Mexican Producers of Phenol


Annual Capacity
as of January 1, 2005
Company and (thousands of
Plant Location metric tons) Process and Remarks

Fenoquimia, S.A. de C.V.


Cosoleacaque, Veracruz (42) Cumene peroxidation. Imported cumene. All
merchant sales. The company filed for
bankruptcy in 2002.

SOURCE: World Petrochemicals Program, SRI Consulting.

SALIENT STATISTICS

The following table presents Mexican salient statistics for phenol:

Mexican Supply/Demand for Phenol


(thousands of metric tons)
Annual Operating
Capacity Rate
(year-end) (percent) Production Imports Exports Consumption

1987 36 97 35 -- 13 21

1992 39 72 28 -- 15 13
1993 39 64 25 2 14 14
1994 39 87 34 3 19 15

1995 39 92 36 5 23 19
1996 39 90 35 6 19 20
1997 39 100 39 6 22 20
1998 40 95 38 5 21 21
1999 40 90 36 6 22 20

2000 40 98 39 8 25 20

*43* phenol CEH DRAFT—2 May 17, 2005-EG


2001 40 75 19 7 11 15
2002 42 0 0 15 neg 15
2003 42 0 0 15 neg 15
2004 42 0 0 20 neg 20

SOURCE: CEH estimates.

Most trade in phenol is between Mexico and the United States.

CONSUMPTION

The following table presents Mexican consumption of phenol:

Mexican Consumption of Phenol


(thousands of metric tons)
Alkyl-
PF Resins Bisphenol Aa phenols Other Total

1987 10 4 2 5 21

1992 8 -- 2 3 13
1993 8 -- 2 4 14
1994 7 -- 2 6 15

1995 9 -- 3 7 19
1996 10 -- 3 7 20
1997 10 -- 3 7 20
1998 11 -- 3 7 21
1999 11 -- 3 6 20

2000 11 -- 3 6 20
2001 11 -- 3 6 20
2002 12 -- 3 neg 15
2003 12 -- 3 neg 15
2004 12 -- 4 4 20

2009 14 -- 5 5 24

Average Annual Growth Rate


(percent)

2004-
2009 3.1% -- 4.6% 4.6% 3.7%
_
a. Bisphenol A production was terminated in 1989.

SOURCE: CEH estimates.

The largest consumers of phenol for PF resins in Mexico are Feno Resinas and Q.B. Químicos.

*44* phenol CEH DRAFT—2 May 17, 2005-EG


SOUTH AND CENTRAL AMERICA

PRODUCING COMPANIES

The following table presents South and Central American producers of phenol:

South and Central American Producers of Phenol


Annual Capacity
as of January 1, 2005
Company and (thousands of
Plant Location metric tons) Process and Remarks

Brazil

Rhodia Brasil Ltda.


Paulínia, São Paulo 165 Cumene peroxidation. Purchased
cumene. Some captive consumption
for bisphenol A and adipic acid.

SOURCE: CEH estimates compiled in association with the World Petrochemicals


Program, SRI Consulting.

SALIENT STATISTICS

The following table presents salient statistics for phenol in South and Central America:

South and Central American Supply/Demand for Phenol—2004


(thousands of metric tons)
Annual
Capacity Net
(year-end) Production Imports Consumption

Argentina 0 0 17 17
Brazil 165 140 10 150
Chile 0 0 11 11
Colombia 0 0 6 6
Venezuela 0 0 1 1
Othera 0 0 1 1

Total 165 140 46 186

a. Includes Ecuador, Nicaragua, Peru and Uruguay.

SOURCE: CEH estimates compiled in association with the World Petrochemicals


Program, SRI Consulting.

*45* phenol CEH DRAFT—2 May 17, 2005-EG


Brazil is the sole producer and largest consumer of phenol in South America. It accounts for nearly 75%

of South American consumption and has a large and established market for PF resins. The following table

presents historical Brazilian salient statistics for phenol:

Brazilian Supply/Demand for Phenol


(thousands of metric tons)
Annual Operating
Capacity Rate Apparent
(year-end) (percent) Production Imports Exports Consumption

1989 102 107 109 24 15 118

1992 115 79 91 10 9 92

1994 120 94 113 15 11 117

1997 120 98 118 20 6 132

2000 140 89 124 36 9 151

2003 140 98 134 11 3 142

SOURCE: CEH estimates compiled in association with the World Petrochemicals Program,
SRI Consulting.

CONSUMPTION

The following table presents South and Central American consumption of phenol:

South and Central American Consumption of Phenol


(thousands of metric tons)
Average Annual
Percent of Growth Rate,
Consumption 2004-2009
2004 in 2004 2009 (percent)

PF Resins 108 58 129 3.6


Adipic Acid 39 21 39 0
Bisphenol A 20 11 28 7.0
Alkylphenols 6 3 7 3.1
Other 13 7 17 5.5

Total 186 100% 220 3.4%

SOURCE: CEH estimates compiled in association with the World


Petrochemicals Program, SRI Consulting.

The following table presents South and Central American consumption of phenol by country for 2004:

*46* phenol CEH DRAFT—2 May 17, 2005-EG


South and Central American Consumption of Phenol by Country—2004
(thousands of metric tons)
PF Resins Adipic Acid Bisphenol A Alkylphenols Other Total

Argentina 11 0 0 0 6 17
Brazil 78 39 20 6 7 150
Chile 11 0 0 0 0 11
Colombia 6 0 0 0 0 6
Venezuela 1 0 0 0 0 1
Othera 1 0 0 0 0 1

Total 108 39 20 6 13 186

a. Includes Ecuador, Nicaragua, Peru and Uruguay.

SOURCE: CEH estimates compiled in association with the World Petrochemicals Program, SRI
Consulting.

The following table presents Brazilian consumption of phenol:

Brazilian Consumption of Phenol


(thousands of metric tons)
PF Adipic
Resins Acid Bisphenol A Nonylphenol Other Total

1989 53 30 15 3 7 108

1992 37 27 9 4 10 87

1994 47 37 15 4 12 115

1997 60 39 17 5 12 133

2001 73 41 17 5 4 140

2004 72 42 22 6 8 150

2009 85 42 31 7 10 175

Average Annual Growth Rate


(percent)

2004-
2009 3.4% 0% 7.1% 3.1% 4.6% 3.1%

SOURCE: CEH estimates compiled in association with the World Petrochemicals


Program, SRI Consulting.

*47* phenol CEH DRAFT—2 May 17, 2005-EG


WESTERN EUROPE

PRODUCING COMPANIES

The following table presents Western European producers of phenol:

Western European Producers of Phenol


Annual Capacity
as of January 1, 2005
Company and (thousands of
Plant Location metric tons) Process and Remarks

Belgium

INEOS Phenol GmbH & Co. KG


Antwerpen 450 Cumene peroxidation. Purchased cumene. All merchant
sales. Plans on expanding capacity to 640 thousand metric
tons per year for start-up in October 2006.

Finland

Borealis Polymers Oy
Porvoo 130 Cumene peroxidation. Captive cumene. All merchant
sales.

France

ATOFINA
Carling-Saint Avold 2 Coal tar extraction.

VFT France SA
Forbach 5 Coal tar extraction. Owned 100% by N.V. VFT Belgium
S.A., Belgium.

Novapex
Les Roches-Roussillon 115 Cumene peroxidation. Captive cumene. Some captive
consumption for aminophenols. Ownership is 80% by
Bain Capital, LLC, Unites States, 17% by Rhodia
S.A., France and 3% by management.

Germany

DOMO Caproleuna GmbH


Leuna 155 Cumene peroxidation. Captive cumene. Mostly captive
consumption for caprolactam.

INEOS Phenol GmbH & Co. KG


Gladbeck 630 Cumene peroxidation. Purchased cumene. All merchant
sales. Expanded by 10 thousand metric tons in September
2003.

RÜTGERS Chemicals AG
Castrop-Rauxel 16 Coal tar extraction.

*48* phenol CEH DRAFT—2 May 17, 2005-EG


Italy

Polimeri Europa SpA


Mantova 300 Cumene peroxidation. Transferred captive cumene. Some
captive consumption for alkylphenols and cyclohexanone.
Porto Torres 180 Cumene peroxidation. Captive cumene. Some phenol is
transferred to other EniChem sites for captive
consumption.

Netherlands

DSM Special Products BV


Botlek-Rotterdam 110 Toluene oxidation. Purchased toluene. Mostly captive
consumption for caprolactam.

Spain

Ertisa, S.A.
Palos de la Frontera 360 Cumene peroxidation. Captive cumene. All merchant
sales.

United Kingdom

Coalite Products Ltd.


Coalite Chemicals Division
Chesterfield 10 Coal tar extraction. All captive consumption.

Total 2,463

SOURCE: CEH estimates compiled in association with the World Petrochemicals Program, SRI Consulting.

SALIENT STATISTICS

The following table presents Western European salient statistics for phenol:

Western European Supply/Demand for Phenol—2004


(thousands of metric tons)
Annual
Capacity
(year-end) Production Imports Exports Consumption

Austria -- -- 21 3 18
Belgium 450 420 166 392 194
Finland 130 130 24 92 62
France 122 120 50 55 115
Germany 801 750 265 268 747
Italy 480 410 24 150 284
Netherlands 110 102 367 54 415
Norway -- -- 3 -- 3
Portugal -- -- 2 -- 2
Spain 360 360 52 236 176
Sweden -- -- 10 2 8
Switzerland -- -- 37 -- 37
United Kingdom 10 8 92 1 99
Otherb -- -- 7 -- 7

*49* phenol CEH DRAFT—2 May 17, 2005-EG


Total 2,463 2,300 1,120 1,253 2,167

a. Rhodia shut down 70 thousand metric tons of phenol capacity at year-end 2000.

b. Includes Denmark, Ireland and Greece.

SOURCE: CEH estimates compiled in association with the World Petrochemicals Program, SRI
Consulting.

The following table presents historical Western European supply/demand for phenol:

Western European Supply/Demand for Phenol


(thousands of metric tons)
Annual
Capacity Operating Rate Net Apparent
(year-end) (percent) Production Exports Consumption

1987 1,244 96 1,191 –4 1,195

1992 1,445 88 1,274 –32 1,306

1994 1,666 87 1,457 60 1,397

1997 1,873 94 1,755 46 1,709

1999 2,443 86 2,101 154 1,947

2003 2,423 93 2,256 149 2,107

SOURCE: World Petrochemicals Program, SRI Consulting.

CONSUMPTION

The following table presents Western European consumption of phenol:

Western European Consumption of Phenol


(thousands of metric tons)
Average Annual
Percent of Growth Rate,
Consumption 2004-2009
2004 in 2004 2009 (percent)

Bisphenol A 928 43 1,216 5.6


PF Resins 532 24 589 2.1
Caprolactam 279 13 279 0
Alkylphenols 100 5 106 1.2
Adipic Acid 66 3 76 2.9
Other 262 12 305 3.1

Total 2,167 100% 2,571 3.5%

SOURCE: CEH estimates compiled in association with the World


Petrochemicals Program, SRI Consulting.

*50* phenol CEH DRAFT—2 May 17, 2005-EG


The following table presents historical Western European consumption of phenol:

Historical Western European Consumption of Phenol


(thousands of metric tons)
Bisphenol A PF Resins Caprolactam Alkylphenols Adipic Acid Other Total

1987 257 320 239 76 24 275 1,191

1992 379 365 327 93 22 226 1,411

1994 355 412 336 102 23 245 1,473

1997 470 494 337 92 25 291 1,709

1999 674 515 341 98 28 292 1,947

2003 855 519 323 98 64 255 2,114

SOURCE: World Petrochemicals Program, SRI Consulting.

Western European consumption of phenol grew 2.2% annually between 1999 and 2004, largely because

of phenol requirements for bisphenol A, which grew at an average annual rate of 6.6% during the same

period. Bisphenol A will continue to be the driving force for phenol demand. Consumption of phenol for

PF resins is forecast to grow at GDP levels.

PRICE

The following table presents German prices for phenol:

German Market and Trade Prices for Phenol


Euros per Kilogram Dollars per Kilogram
Exchange Rate
Average Market Pricea Tradeb Average Market Pricea Tradeb (Euros per
Prices Prices dollar)
1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q

2002 0.40 0.65 0.69 0.67 0.55-0.56 0.38 0.61 0.65 0.63 0.52-0.53 1.058
2003 0.63 0.73 0.57 0.63 0.57-0.59 0.71 0.83 0.65 0.71 0.65-0.67 0.883
2004 0.71 0.62 1.35 1.20 0.74-0.80 0.88 0.77 1.68 1.49 0.92-0.99 0.804
2005 0.95 -- -- -- -- 1.25 -- -- -- -- 0.762

a. Prices are for mid-quarter.


b. Data are trade prices (the range of import/export prices).
SOURCES: (A) CEH estimates (data for Average Market Price).

(B) Global Trade Information Systems (data for Trade Prices).

*51* phenol CEH DRAFT—2 May 17, 2005-EG


The following table presents historical German prices for phenol:

Historical German Prices for Phenol (1982-2001)a


DM per Kilogram
List/Spot Priceb Contract Price
1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q

1982 1.81 1.70 1.80 -- 1.83 1.60 1.75 1.70


1983 -- -- -- -- 1.68 1.20 1.58-1.65 1.70-1.80
1984 -- -- -- -- 1.78 1.72 1.75 1.65

1985 -- -- -- -- 1.65 1.65 1.80 1.91


1986 -- -- -- -- 1.29 1.45 0.92 1.00
1987 -- -- 1.65 1.45 1.02 1.02 1.45 1.48
1988 1.55 1.70 2.00 2.25 1.60 1.60 1.75 1.85
1989 2.18 1.98 1.85 1.65 1.85 2.00 1.80 1.70

1990 1.40 1.32 1.25 1.40 1.50 1.40 1.40 1.40


1991 1.20 0.95 0.86 1.00 1.60 1.00 0.94 1.00
1992 0.97 0.90 1.02 0.75 1.00 1.02 1.05 1.00
1993 0.80 0.76 0.76 0.83 0.90 0.98 0.97 0.86
1994 0.85 0.91 1.05 1.23 0.88 0.91 1.03 1.15

1995 1.09 1.37 1.20 1.05 1.40 1.40 1.28 1.12


1996 0.95 1.10 1.20 1.20 0.95 -- -- --
1997 1.20 1.30 1.35 1.50 -- -- -- --
1998 1.60 1.50 1.30 1.05 1.60 1.40 1.30 0.95
1999 0.81-0.85 0.81-0.88 0.85-0.90 0.98-1.11 0.92-0.97 0.92-1.00 0.99-1.03 1.04-1.21

2000 1.13-1.20 1.60-1.65 1.68-1.78 1.85-1.90 1.25-1.30 1.60-1.67 1.83-1.86 1.85-1.90


2001 1.60-1.65 1.47-1.50 1.25-1.35 0.98 1.84-1.86 1.70-1.72 1.46-1.49 1.10

U.S. Cents per Kilogram


List/Spot Priceb Contract Price
1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q

1982 80 71 73 -- 81 67 71 67
1983 -- -- -- -- 70 50 62-65 64-68
1984 -- -- -- -- 64 66 63 54

1985 -- -- -- -- 53 53 59 71
1986 -- -- -- -- 52 64 42 49
1987 -- -- 92 79 53 56 81 81
1988 98 102 110 120 101 96 96 99
1989 124 104 95 87 105 105 92 90

1990 81 78 76 90 87 82 85 90
1991 79 56 48 60 105 59 52 60
1992 63 55 67 53 65 62 69 70
1993 49 47 45 52 56 61 58 53
1994 49 54 66 79 51 54 64 74

1995 69 99 87 73 89 101 92 78
1996 65 72 80 78 66 -- -- --
1997 72 76 75 86 -- -- -- --
1998 88 77 72 63 88 77 72 57

*52* phenol CEH DRAFT—2 May 17, 2005-EG


1999 48-50 44-47 46-49 50-57 55-58 50-54 54-56 53-62

2000 57-60 76-79 75-79 82-85 63-65 76-80 81-83 82-85


2001 75-78 67-69 57-61 45 84-85 78-79 67-68 50

a. Includes former German Democratic Republic after 1990. Data reflect a range of high and low prices
taken over the entire year.

b. Data are list prices during 1982-1987 and spot prices beginning in 1988.

SOURCE: (A) World Petrochemicals Price Update, World Petrochemicals Program, SRI Consulting
(data for 1982-1995).

(B) CEH estimates (data for 1996-2001).

CENTRAL AND EASTERN EUROPE

PRODUCING COMPANIES

The following table presents central and Eastern European producers of phenol:

Central and Eastern European Producers of Phenol


Annual Capacity
as of January 1, 2005
Company and (thousands of
Plant Location metric tons) Process and Remarks

Bulgaria

Lukoil Neftochim
Burgas 40 Cumene peroxidation. Captive cumene. Some captive
consumption for PF resins.

Czech Republic

DEZA a.s.
Valasské Mezirici 10 Coal tar extraction.

Poland

Polski Koncern Naftowy


ORLEN S.A.
Plock 53 Cumene peroxidation. Captive cumene. All merchant sales.

Romania

Carom
Onesti 42 Cumene peroxidation. Captive cumene. All merchant sales.

Petrochim
Brazi (75) Cumene peroxidation. Captive cumene. All merchant sales.
Idle since 1998.

*53* phenol CEH DRAFT—2 May 17, 2005-EG


Russia

Kazanorgsintez
Kazan 65 Cumene peroxidation. Captive cumene. All merchant sales.

Novokuibyshevsky
Novokuibyshevsky 17 Cumene peroxidation. Captive cumene. All merchant sales.

Orgsteklo
Dzershinsk 45 Cumene peroxidation. Captive cumene. All merchant sales.

Samarsk Zavod
Samara 75 Cumene peroxidation. Captive cumene. All merchant sales.

Saratovorgsintez
Saratov 45 Cumene peroxidation. Captive cumene. All merchant sales.

Ufaorgsyntez
Ufa 72 Cumene peroxidation. Captive cumene. Some captive
consumption for bisphenol A.

Slovakia

Slovnaft a.s.
Bratislava 35 Cumene peroxidation. Captive cumene. All merchant sales.

Total 499

SOURCE: CEH estimates compiled in association with the World Petrochemicals Program, SRI Consulting.

SALIENT STATISTICS

The following table presents salient statistics for phenol in central and Eastern Europe:

Central and Eastern European Supply/Demand for Phenol—2004


(thousands of metric tons)
Annual
Capacity Net
(year-end) Production Imports Consumption

Czech Republic 10 6 1 7
Hungary 0 0 0 0
Poland 53 45 22 67
Romania 42 25 2 27
Russiaa 319 203 –51 152
Slovakia 35 33 –31 2
Otherb 40 20 11 31

Total 499 332 –46 286

a. Includes other states of the former USSR. Includes some phenol production from coal
operations.

b. Includes Bulgaria, Croatia, Slovenia and the former Yugoslavia.

SOURCE: CEH estimates compiled in association with the World Petrochemicals

*54* phenol CEH DRAFT—2 May 17, 2005-EG


Program, SRI Consulting.

CONSUMPTION

The following table presents central and Eastern European consumption of phenol:

Central and Eastern European Consumption of Phenol


(thousands of metric tons)
Average Annual
Percent of Growth Rate,
Consumption 2004-2009
2004 in 2004 2009 (percent)

PF Resins 110 39 131 3.5


Bisphenol A 60 21 70 3.0
Caprolactam 52 18 52 0
Alkylphenols 21 7 23 1.8
Other 43 15 47 2.0

Total 286 100% 323 2.5%

SOURCE: CEH estimates compiled in association with the World


Petrochemicals Program, SRI Consulting.

JAPAN

PRODUCING COMPANIES

The following table presents Japanese producers of phenol:

Japanese Producers of Phenol


Annual Capacity
as of January 1, 2005
Company and (thousands of
Plant Location metric tons) Process and Remarks

Air Water Chemicals Inc.


Kashima, Ibaraki Prefecture 2 Coal tar extraction.

Chiba Phenol Co., Ltd.


Ichihara, Chiba Prefecture 200 Cumene peroxidation. Captive cumene from part owner
Mitsui Chemicals. Jointly owned by Mitsui Chemicals
(55%) and Idemitsu Petrochemical Co., Ltd. (45%).
Some captive consumption for bisphenol A by Idemitsu.

JFE Chemical Corporation


Kasaoka, Okayama Prefecture 2 Coal tar extraction.

Mitsubishi Chemical Corporation


Kashima, Ibaraki Prefecture 250 Cumene peroxidation. Captive cumene. Some captive
consumption for bisphenol A.

*55* phenol CEH DRAFT—2 May 17, 2005-EG


Mitsui Chemicals, Inc.
Ichihara, Chiba Prefecture 190 Cumene peroxidation. Captive cumene. Some captive
consumption for aniline.
Takaishi, Osaka Prefecture 200 Cumene peroxidation. Captive cumene. Some captive
consumption for bisphenol A, nonylphenol and PF
resins.

Nippon Phenol Company, Ltd.


Kitakyushu, Fukuoka Prefecture 120 Toluene oxidation. Owned 87.5% by Nippon Steel
Chemical Co., Ltd. and 12.5% by Mitsubishi Chemical
Corporation. All merchant sales.

Nippon Steel Chemical Co., Ltd.


Kitakyushu, Fukuoka Prefecture 10 Coal tar extraction.

Total 974

SOURCE: CEH estimates compiled in association with the World Petrochemicals Program, SRI Consulting.

SALIENT STATISTICS

The following table presents Japanese salient statistics for phenol:

Japanese Supply/Demand for Phenol


(thousands of metric tons)
Annual Operating
Capacity Rate
(year-end) (percent) Production Imports Exports Consumption

1987 382 82 313 20 55 296

1992 904 60 538 8 75 450

1994 904 76 690 6 122 589

1997 904 92 833 2 170 673

2001 904 90 884 10 126 768

2004 974 99 966 1 87 880

SOURCE: CEH estimates compiled in association with the World Petrochemicals Program, SRI
Consulting.

CONSUMPTION

The following table presents Japanese consumption of phenol:

*56* phenol CEH DRAFT—2 May 17, 2005-EG


Japanese Consumption of Phenol
(thousands of metric tons)
Average Annual
Percent of Growth Rate,
Consumption 2004-2009
2004 in 2004 2009 (percent)

Bisphenol A 493 56 544 2.0


PF Resins 180 20 200 2.1
Aniline 130 15 130 0
Xylenols 30 4 33 1.9
Other 47 5 50 1.2

Total 880 100% 957 1.7%

SOURCE: CEH estimates compiled in association with the World


Petrochemicals Program, SRI Consulting.

The following table presents historical Japanese consumption of phenol:

Historical Japanese Consumption of Phenol


(thousands of metric tons)
PF Resins Bisphenol A Aniline Xylenols Other Total

1987 114 93 41 22 26 296

1992 106 168 86 31 59 450

1994 100 221 91 29 148 589

1997 71 301 108 35 158 673

2003 178 483 130 30 53 874

SOURCE: CEH estimates compiled in association with the World Petrochemicals Program,
SRI Consulting.

Japanese consumption of phenol grew 4.6% annually between 2001 and 2004, largely because of phenol

requirements for bisphenol A, which grew at an average annual rate of nearly 5% during the same period.

Consumption of phenol for PF resins grew at an average annual rate 5.6% from 2001 to 2004. The PF

resin market in Japan will likely see decreased growth as more wood products are being manufactured in

Southeast Asia.

*57* phenol CEH DRAFT—2 May 17, 2005-EG


PRICE

The following table presents Japanese unit sales values and trade prices for phenol:

Japanese Unit Sales Values and Trade Prices for Phenol


Yen per Kilogram Cents per Kilogram
Unit Sales Tradea Unit Sales Tradea Exchange Rate
Value Prices Value Prices (yen per dollar)
1999 262 61-76 230 54-67 114
2000 255 70-75 237 65-70 108
2001 258 72-78 212 59-64 122
2002 256 76-79 204 61-63 125
2003 265 79-81 229 68-70 116
2004 259 102-106 239 94-98 108

a. Data are trade prices (the range of import/export prices).


SOURCE: Yearbook of Chemical Industries Statistics, Ministry of
International Trade and Industry.

The following table presents historical Japanese quarterly list prices for phenol:

Historical Japanese List Prices for Phenol—1982-2000


Yen per Kilogram Cents per Kilogram
1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q

1982 255 250-270 250-270 250-270 116 104-113 100-108 96-104


1983 250-270 250-270 250-270 250-270 109-117 104-113 104-113 104-113
1984 265-285 265-285 265-285 265-285 113-121 118-127 112-120 108-116

1985 265-285 265-285 265-285 265-285 106-114 104-112 106-114 120-130


1986 265-285 260-280 -- -- 131-140 145-156 -- --
1987 -- -- -- -- -- -- -- --
1988 -- -- -- -- -- -- -- --
1989 -- -- -- -- -- -- -- --

1990 -- -- 265-275 265-275 -- -- 174-181 183-190


1991 293-303 293-303 278-288 278-288 227-235 215-223 200-207 203-210
1992 265-275 240-250 230-245 210-230 207-215 182-189 180-191 172-189
1993 220-240 220-240 220-240 220-250 177-194 188-205 202-220 210-238
1994 220-250 220-250 220-250 235-265 204-232 210-238 210-238 237-268

1995 235-265 235-265 235-265 235-265 240-270 237-268 280-316 258-291


1996 235-265 235-265 235-277 245-277 222-250 218-246 218-254 217-246
1997 245-277 259-295 259-295 259-295 202-229 217-247 220-250 207-235
1998 246-263 242-273 249-271 242-261 188-201 185-209 190-207 185-200
1999 237-265 253-269 257-289 255-264 209-234 223-238 224-256 225-234

2000 235-270 221-263 252-278 236-260 218-250 205-244 234-258 219-241

SOURCE: World Petrochemicals Price Update, World Petrochemicals Program, SRI Consulting.

*58* phenol CEH DRAFT—2 May 17, 2005-EG


OTHER ASIA

PRODUCING COMPANIES

The following table presents other Asian producers of phenol:

Other Asian Producers of Phenol


Annual Capacity
as of January 1, 2005
Company and (thousands of
Plant Location metric tons) Process and Remarks

China

Harbin Huayu Co. Ltd.


Harbin, Heilongjiang 31 Cumene peroxidation. Captive cumene. All
merchant sales. Expansion to 76 thousand metric
tons is planned for 2005.

Petrochina Jilin Chemical Industrial


Jilin, Jilin 156 Cumene peroxidation. Captive cumene. All
merchant sales. Expansion to 230 thousand metric
tons is planned for 2005.
Sinopec Beijing Yanhua Petrochemical Co.
Ltd.
Beijing 150 Cumene peroxidation. Captive cumene. Some
captive consumption for caprolactam.

Sinopec Shanghai Gaoqiao Petrochemical


Corp.
Shanghai 200 Cumene peroxidation. Captive cumene. All
merchant sales.

India

Hindustan Organic Chemicals Ltd.


Cochin, Kerala 52 Cumene peroxidation. Captive cumene. All
merchant sales.

Schenectady Herdillia Ltd.


Navi Mumbai, Maharashtra 34 Cumene peroxidation. Captive cumene. Some
captive consumption for alkylphenols. Majority
owned by Schenectady International, Inc.

Korea, Republic of

Kumho P & B Chemicals, Inc.


Yeochon, Chollanam-do 130 Cumene peroxidation. Captive cumene. Some
(150) captive consumption for bisphenol A. Started a 150
thousand metric tons-per-year unit in March 2005.

LG Petrochemical
Yeochon, Chollanam-do (150) Cumene peroxidation. Captive cumene. Started
limited production in April 2005. Some captive
consumption for BPA.

*59* phenol CEH DRAFT—2 May 17, 2005-EG


Singapore

Mitsui Phenol Singapore Pte. Ltd.


Jurong 250 Cumene peroxidation. Captive cumene. Mostly
captive consumption for bisphenol A by Mitsui
Bisphenol Singapore Pte. Ltd.

Taiwan

Chang Chun Petrochemical Co. Ltd.


Kaohsiung, Kaohsiung Hsien (200) Cumene peroxidation. Captive cumene. Came on
stream in March 2005.

Formosa Chemicals & Fibre Corp.


Mailiao City, Yunlin Hsien 400 Cumene peroxidation. Captive cumene. All
merchant sales, mainly to affiliate Nan Ya for
bisphenol A.

Taiwan Prosperity Chemical Corporation


Linyuan City, Kaohsiung Hsien 140 Cumene peroxidation. Captive cumene. Some
captive consumption for bisphenol A.

Total 1,543

SOURCE: CEH estimates compiled in association with the World Petrochemicals Program, SRI Consulting.

Several new plants or expansions are planned for 2005-2007. Some of the companies planning additional

phenol capacity include Shanghai Gaoqiao (expanding to 250 thousand metric tons), Petrochina Jilin

Chemical (expanding to 230 thousand metric tons), Harbin (expanding to 76 thousand metric tons),

Jiangsu Nantong (building a 124 thousand metric tons-per-year plant) and Kingboard Chemical (planning

a 125 thousand metric tons-per-year plant).

Salient Statistics

The following table presents other Asian salient statistics for phenol by country in 2004:

Other Asian Supply/Demand for Phenol—2004


(thousands of metric tons)
Annual
Capacity
(year-end) Production Imports Exports Consumption

China 537 370 281 3 648


India 86 80 70 5 145
Indonesia -- -- 25 -- 25
Korea, Republic of 130 121 97 7 211
Malaysia -- -- 44 10 34
Pakistan -- -- 3 -- 3
Philippines -- -- 4 -- 4
Singapore 250 240 15 15 240

*60* phenol CEH DRAFT—2 May 17, 2005-EG


Taiwan 540 420 22 72 370
Thailand -- -- 171 -- 171
Other -- -- 2 -- 2

Total 1,543 1,231 734 112 1,853

SOURCE: CEH estimates compiled in association with the World Petrochemicals Program, SRI
Consulting.

CONSUMPTION

The following table presents other Asian consumption of phenol:

Other Asian Consumption of Phenol


(thousands of metric tons)
Average Annual
Percent of Growth Rate,
Consumption 2004-2009
2004 in 2004 2009 (percent)

Bisphenol A 745 40 1,315 12.0


PF Resins 555 30 710 5.0
Alkylphenols 49 3 63 5.1
Adipic Acid 33 2 40 3.9
Other 471 25 535 2.6

Total 1,853 100% 2,663 7.5%

SOURCE: CEH estimates compiled in association with the World


Petrochemicals Program, SRI Consulting.

OTHER REGIONS

PRODUCING COMPANIES

The following table presents major producers of phenol in other regions:


Major Producers of Phenol in Other Regions
Annual Capacity
as of January 1, 2005
Company and (thousands of
Plant Location metric tons) Process and Remarks

AFRICA

South Africa

Merisol RSA (Pty) Ltd.


Sasolburg 44 Coal tar extraction. Some captive consumption
for alkylphenols.

*61* phenol CEH DRAFT—2 May 17, 2005-EG


OCEANIA

Australia

Huntsman Chemical Australia Ltd.


West Footscray, Victoria 22 Cumene peroxidation. Captive cumene. Some
captive consumption for PF resins.

Total 66

SOURCE: CEH estimates compiled in association with the World Petrochemicals Program, SRI Consulting.

SALIENT STATISTICS

The following table presents salient statistics for phenol in other regions in 2004:

Supply/Demand for Phenol in Other Regions—2004


(thousands of metric tons)
Annual
Capacity
(year-end) Production Imports Exports Consumption

Africa

Algeria -- -- 0 -- 0
Egypt -- -- 4 -- 4
South Africa 44 40 -- 30 10

Middle East

Iran -- -- 15 -- 15
Israel -- -- 5 -- 5
Saudi Arabia -- -- 3 -- 3
Turkey -- -- 11 -- 11

Oceania

Australia 22 16 3 2 17
New Zealand -- -- 0 -- 0

Total 66 56 41 32 65

SOURCE: CEH estimates compiled in association with the World Petrochemicals Program, SRI
Consulting.

CONSUMPTION

The following table presents consumption of phenol in other regions:

*62* phenol CEH DRAFT—2 May 17, 2005-EG


Consumption of Phenol in Other Regions
(thousands of metric tons)
Average Annual
Percent of Growth Rate,
Consumption 2004-2009
2004 in 2004 2009 (percent)

PF Resins 39 60 45 2.9
Bisphenol A 10 15 25 20.1
Other 17 26 20 3.3

Total 65 100% 90 6.7%

SOURCE: CEH estimates compiled in association with the World


Petrochemicals Program, SRI Consulting.

BIBLIOGRAPHY

Chemical Economics Handbook—The following CEH marketing research reports, product reviews and

data summary contain additional information that is pertinent to the subject of this report:

Acetone

Adipic Acid

Aniline

Bisphenol A

Caprolactam

Cresols, Xylenols and Cresylic Acid

Cyclohexane

Cyclohexanol and Cyclohexanone—United States

Epoxy Resins

Phenolic Resins

Polycarbonate Resins

Propylene

*63* phenol CEH DRAFT—2 May 17, 2005-EG


Process Economics Program—The following Process Economics Program reports contain more detailed

information on the manufacturing processes, process design and process economics of phenol and some

of its major derivatives. Address inquiries concerning this information to the Process Economics

Program, SRI Consulting, Menlo Park, California 94025.

Adipic Acid, Report Nos. 3 and 3A, March 1965 and October 1971.

Bisphenol A and Alkylated Phenols, Report No. 192, December 1988.

Caprolactam, Report Nos. 7/1-7/2, 7A and 7B, September 1965, March 1968 and January 1976.

Phenol, Report Nos. 22, 22A, 22B and 22C, April 1967, September 1972, December 1977 and March

1991.

Other References—The following list of additional references is suggested for supplemental reading:

“Big Snip in the Offing,” Asian Chemical News, June 20, 2004.

“Phenol,” Kirk-Othmer Encyclopedia of Chemical Technology, 4th ed., vol. 18, John Wiley & Sons, New

York, 1996, p. 592.

“Phenol,” Ulmann’s Encyclopedia of Industrial Chemistry, 5th ed., vol. A19, VCH Verlagsgesellschaft

mbH, Germany, 1991, p. 299.

“Phenol and Acetone Market Plagued by Continuing Overcapacity,” Chemical Market Reporter, March 4,

2002.

“Phenol Demand is Stable While Acetone Firms,” Chemical Market Reporter, October 27, 2003.

“Sunoco Eyes More Acquistions,” Chemical Week, March 23, 2005, p.28.

*64* phenol CEH DRAFT—2 May 17, 2005-EG

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