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DRAFT Phenol
DRAFT Phenol
PHENOL
By
Elvira O. Camara Greiner
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forecasts pertaining to the international competitive market environment for chemical
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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
BIBLIOGRAPHY....................................................................................................................................... 63
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
d. Includes Indonesia, Malaysia, Pakistan, the Philippines, Thailand, Vietnam and the Democratic People’s
Republic of Korea.
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
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
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
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.
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:
The following table presents world consumption of phenol by region in 2004 and estimates for 2009:
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
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
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
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:
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
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
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
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.
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
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-
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:
OH
COOH
+ O2 2 + 2 CO2
2
The yield of phenol from toluene is believed to be only about 68% of theoretical, corresponding to 1.44
NATURAL RECOVERY
Most natural phenol originates from petroleum caustic wash streams consisting primarily of cresols; only
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
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
SO3Na ONa
+ 2 NaOH + Na2SO3 + H 2O
sodium sodium
benzenesulfonate phenolate
ONa OH
H2SO 4
2 + SO2 + H 2O 2 + Na2SO3
sodium
phenolate phenol
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
Cl
+ Cl2 + HCl
benzene chlorobenzene
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
ONa OH
H2SO 4
2 + SO2 + H 2O 2 + Na2SO3
sodium
phenolate phenol
The yield of phenol by this process is about 82% of theoretical based on benzene and 95% based on
chlorobenzene.
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
about 480°C over a suitable catalyst produces phenol and hydrochloric acid:
Cl
+ HCl + 1/2 O2 + H 2O
benzene chlorobenzene
Cl OH
+ H2O + HCI
chlorobenzene phenol
The yield of phenol by the Raschig process is believed to be about 89% of theoretical based on benzene.
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
phenol.
catalyst
+ 2 H2
H2O
benzene cyclohexene
O OH
O2
+ 3 H2 + 2 H2
catalyst catalyst
benzene, which is recycled and used in the initial hydrogenation step. Hydrogen produced in the
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.
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
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.
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.
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).
UNITED STATES
PRODUCING COMPANIES
Noveon Inc.
Kalama, WA 34 Toluene oxidation Purchased toluene. Some captive consumption for
alkylphenols.
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).
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.
PRODUCTION
Synthetica
Sales
From From Other
Cumene Processes Total Natural Total Synthetic Natural
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):
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).
Cumene peroxidation has been the primary source of phenol since 1967. Cumene-based phenol accounted
CONSUMPTION
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.
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
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.
Polycarbonate Resins 71
Epoxy Resins 23
Flame Retardants 4
Other 2
Total 100%
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
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
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,
For additional information, see the CEH Bisphenol A product review and the CEH Polycarbonate Resins
PF Resins
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
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.
Wood Adhesives
Fibrous and Granulated Wood 35
Plywood 21
Insulation 14
Laminates 8
Foundry Materials 7
Molding Compounds 5
Other 10
Total 100%
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
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.
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
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
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
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,
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
The following table presents U.S. caprolactam production from phenol and phenol consumed in its
production:
1965 82 62 73
1970 120 52 108
1975 145 45 131
1980 185 45 166
Nylon 6 Fibers 71
Nylon 6 Resins and Films 27
Other 2
Total 100%
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
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
For additional information, see the CEH Caprolactam marketing research report.
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-
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
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
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
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
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.
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.
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
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
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.
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:
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
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-
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
United States. The 2,4- and 2,6- isomers are used mainly as intermediates in the production of
z Other alkylphenols include amylphenols (used in PF resins, germicides and oil field chemicals),
Other
Data for “Other” include phenol requirements for other alkylphenols, discussed in the section
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
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
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
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)
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
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
PRICE
The following table presents U.S. contract prices and unit export values for phenol:
Contract Price
Unit Export
a. Price bases are synthetic, fob, shipping point, freight equalized, nearest
recognized producing point.
Generally, phenol prices correlate strongly with propylene and benzene prices. Variations in supply and
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
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
TRADE
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
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
The following table presents U.S. exports of phenol by country of destination in 2004:
CANADA
SALIENT STATISTICS
1987 60 53 27 1 79 73 2 3
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
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).
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
SALIENT STATISTICS
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
CONSUMPTION
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
2004-
2009 3.1% -- 4.6% 4.6% 3.7%
_
a. Bisphenol A production was terminated in 1989.
The largest consumers of phenol for PF resins in Mexico are Feno Resinas and Q.B. Químicos.
PRODUCING COMPANIES
The following table presents South and Central American producers of phenol:
Brazil
SALIENT STATISTICS
The following table presents salient statistics for phenol in South and Central America:
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
of South American consumption and has a large and established market for PF resins. The following table
1992 115 79 91 10 9 92
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:
The following table presents South and Central American consumption of phenol by country for 2004:
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
SOURCE: CEH estimates compiled in association with the World Petrochemicals Program, SRI
Consulting.
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
2004-
2009 3.4% 0% 7.1% 3.1% 4.6% 3.1%
PRODUCING COMPANIES
Belgium
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
RÜTGERS Chemicals AG
Castrop-Rauxel 16 Coal tar extraction.
Netherlands
Spain
Ertisa, S.A.
Palos de la Frontera 360 Cumene peroxidation. Captive cumene. All merchant
sales.
United Kingdom
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:
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
a. Rhodia shut down 70 thousand metric tons of phenol capacity at year-end 2000.
SOURCE: CEH estimates compiled in association with the World Petrochemicals Program, SRI
Consulting.
The following table presents historical Western European supply/demand for phenol:
CONSUMPTION
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
PRICE
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
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
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).
PRODUCING COMPANIES
The following table presents central and Eastern European producers of phenol:
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
Romania
Carom
Onesti 42 Cumene peroxidation. Captive cumene. All merchant sales.
Petrochim
Brazi (75) Cumene peroxidation. Captive cumene. All merchant sales.
Idle since 1998.
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:
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
a. Includes other states of the former USSR. Includes some phenol production from coal
operations.
CONSUMPTION
The following table presents central and Eastern European consumption of phenol:
JAPAN
PRODUCING COMPANIES
Total 974
SOURCE: CEH estimates compiled in association with the World Petrochemicals Program, SRI Consulting.
SALIENT STATISTICS
SOURCE: CEH estimates compiled in association with the World Petrochemicals Program, SRI
Consulting.
CONSUMPTION
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.
The following table presents Japanese unit sales values and trade prices for phenol:
The following table presents historical Japanese quarterly list prices for phenol:
SOURCE: World Petrochemicals Price Update, World Petrochemicals Program, SRI Consulting.
PRODUCING COMPANIES
China
India
Korea, Republic of
LG Petrochemical
Yeochon, Chollanam-do (150) Cumene peroxidation. Captive cumene. Started
limited production in April 2005. Some captive
consumption for BPA.
Taiwan
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
Salient Statistics
The following table presents other Asian salient statistics for phenol by country in 2004:
SOURCE: CEH estimates compiled in association with the World Petrochemicals Program, SRI
Consulting.
CONSUMPTION
OTHER REGIONS
PRODUCING COMPANIES
AFRICA
South Africa
Australia
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:
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
PF Resins 39 60 45 2.9
Bisphenol A 10 15 25 20.1
Other 17 26 20 3.3
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
Cyclohexane
Epoxy Resins
Phenolic Resins
Polycarbonate Resins
Propylene
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
Adipic Acid, Report Nos. 3 and 3A, March 1965 and October 1971.
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
“Phenol,” Ulmann’s Encyclopedia of Industrial Chemistry, 5th ed., vol. A19, VCH Verlagsgesellschaft
“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.