Faculty of engineering

Alexandria university
Specialized scientific program (SSP)
Gas & petrochemicals engineering department
Petrochemical industries GPE442

Submitted to : Engineer . micheal

Aya Allah Mahmoud 5632

Abeer Hesham 5185

Mahmoud Abdulmohsen 4810

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Title Page No.
1. Introduction 3
2. What is Styrene 3
3. Styrene Characteristics 3
4. History of Styrene 4
5. Common uses of Styrene 4
6. Is Styrene harmful? 4
7. Polystyrene’s Structure 5
8. Polymerization 5
9. Production of styrene 5

10. Market Survey on Styrene 6

Production

11. References 15

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1. Introduction
Styrene is well known as the most important monomer used to produce numerous types of
polymers such as polystyrene, foamed plastics, styrene-modified polyesters, ABS or SAN.
Currently, the global production of styrene is over 30 million tons per year.

The main method for the industrial production of styrene from the 30′s of the twentieth
century to the present time consists on dehydrogenation of ethylbenzene over iron oxide
catalysts.

2. What is Styrene

Styrene is a colorless, flammable liquid, which has a sweet odor and is highly volatile.
Styrene is widely used to make plastics and rubber, which are used to manufacture a variety
of products, such as insulation, pipes, automobile parts, printing cartridges, food containers,
and carpet backing.

High Impact Polystyrene (HIPS), often referred to as styrene, is an easily machined and
fabricated impact-resistant, versatile, and economical plastic.

HIPS is often the preferred material for low strength structural applications. Its excellent
dimensional stability, an affinity for paint, and glue make it an obvious choice for machining
pre-production prototypes.

3. Styrene Characteristics

● Maintains strength in high-impact applications

● Can be painted
● Recyclable with good property retention
● Easily moldable
● FDA compliant grades
● Good dimensional stability
● Good gloss
● Low volatility

Additionally, polystyrene is considered a thermoplastic polymer, a classification that

is determined by the material's reaction to heat. Thermoplastic polymers can be easily
melted and reformed, making them easy to recycle. In contrast, thermoset polymers
can only undergo the forming process once, making them more difficult to recycle.

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4. History of Styrene

Eduard Simon accidentally discovered polystyrene in 1893, when he isolated a monomer

from the resin, storax. The implications of this would not be recognized until later, when
Hermann Staudinger, realized that Simon's discovered material was, in fact, a plastic
polymer. In 1922, Staudinger published his discoveries, noting the similarities between
natural rubbers and polystyrene, which were also composed of monomers. These findings
would earn him the Nobel Prize in 1953.

5. Common Uses of Styrene

BASF began to manufacture polystyrene in 1939 for commercial use. Since then, high
impact styrene plastic has been used in a wide variety of applications including countertop
POP displays and indoor signs, since it is easily thermoformable; excellent for vacuum
forming. Consider the following applications:

5.1 Framing

Styrene plastic is often used for framing due to its shatter-resistant and light-weight
qualities. It is also cost-effective material, making it a good choice for consumers looking for
a mode affordable option.

5.2 Displays

HIPS is often used in point of purchase or retail displays due to its strength and flexibility.
You can often also see this material used in signage, promoting products or sales

6. Is Styrene Harmful?

Styrene plastic is safe in the small quantities found consumers may encounter in food or air.
Long exposure to styrene in close quarters can make some people feel nauseous or result in
eye irritation. Fresh air can help resolve these symptoms.

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7. Polystyrene’s Structure

Polystyrene is a long chain hydrocarbon and is written as C8H8. The hydrogen bonds to the
carbon in an alternating pattern via Van der Waals attractions (or the weak attraction of
atoms and molecules of opposite charges). This weak force accounts for many of
polystyrene's characteristics such as flexibility.

8. Polymerization

Polystyrene is formed when styrene monomers join together. This process breaks apart the
carbon-carbon π bond. During this chemical reaction, a carbon-carbon σ bond is created,
which is stronger and makes it difficult to convert the polymer back into its original parts.

9. styrene production

Ethylbenzene (EB) is produced in by combining Benzene and Ethylene in catalytic

alkylation reaction under liquid state. Most of EB produced is used as an intermediate of
production of styrene, it also used for anti-knocking agent in gasoline, rubber adhesives,
paint, solvent in inks etc.

Benzene(C6H6)+ Ethylene(C2H4) → Ethylbenzene(C6H5(C2H5))

Styrene monomer (SM) is produced by catalytic dehydration reaction of ethylbenzene at gas

phase under high temperature with steam and vacuum condition. Styrene monomer is
allowed to be polymerized to produce commercial products such as polystyrene, ABS,
styrene-butadiene (SBR) rubber, styrene-butadiene latex etc.

Ethylbenzene(C6H5(C2H5)) → Styrene(C6H5(CH=CH2)) + Hydrogen(H2)

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Final product quality control in styrene production
Commercially, styrene is used as a feedstock for polymerization and copolymerization.

Styrene is mostly manufactured by dehydrogenation.

In the dehydrogenation process, fresh and recycled ethylbenzene is mixed with steam and
heated to the required reaction temperature in a heat exchanger. The mixture then continues
to the reactors form where the hot effluent goes to preheating of ethylbenzene-steam mixture.
Then, the condensed reactor effluent is separated into vent gas, condensate and crude
styrene. Afterwards, styrene is purified using the distillation train.

10. Market Survey on Styrene Production:

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styrene Market Analysis
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The global styrene market is estimated to be at 32.7 million tons by the end of this year. It is
projected to reach 42.37 million tons in the next five years, registering a CAGR of over
5.32% during the forecast period.

The COVID-19 pandemic negatively impacted the styrene market. However, the market
recovered significantly in 2021, owing to rising consumption of various industries, such as
packaging, construction, automotive, and others.

• Over the short term, the growing demand from the consumer electronics industry is a
major factor driving the growth of the market studied.

• However, increasing usage of bio-based plastics in the packaging industry is likely to

restrain the growth of the market.

• Nevertheless, ongoing research to develop bio-based polystyrene is likely to create

lucrative growth opportunities for the global market soon.

• The Asia-Pacific region dominates the styrene market, with the largest consumption
coming from countries such as China, Japan, ASEAN countries, etc.

Market Growth Drivers:

• The numerous applications of styrene in plastic packaging, insulation, disposable cups

and containers, etc. are presently driving the market growth.

• Acrylonitrile butadiene styrene (ABS), owing to its performance characteristics, is an

important material in manufacturing of a number of medical equipment.

• ABS is largely used in 3D printing applications by OEMs. The rigidity and heat
resistant capability of ABS makes it the best alternative for metals in different
structural parts. It is also used automotive industry to reduce the overall vehicle weight
and increase fuel efficiency.

Market Restraints

• The adverse effects of styrene on human health such as fatigue, headache, vomiting,
and nausea, when worked in close proximity is restricting its usage. Also, the
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 improper disposal practice of styrene adds to environmental effects such as global
warming. As a result, governments are planning to take necessary measures to limit
the usage of styrene or promote the use of substitute products, which might hinder the
market growth of styrene in near term.

• Divinylbenzene is a derivative of benzene and has structure similar to that of styrene.

It is easily available in the market and can partially or completely replace styrene.
Thus, rising usage of divinylbenzene in the manufacturing processes of plastics,
adhesives, ceramics, and specialty polymers is hindering the growth of styrene market
to some extent.

• The factor known as bio-plastic which is derived for plants such as sugarcane, corn
and other forms of cellulose can act as a restraint for the market growth.

Market Opportunities:

• The expanded polystyrene can be manufactured from materials which can be recycled.
As a result, it is widely used in sustainable packaging products.

• Expanded styrene is largely being used for packaging purpose in e-commerce, fast
moving consumer goods (FMCG), household electrical devices, and personal care
sectors. This trend is expected to continue in near future which has created ample
opportunities for styrene producers.

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 10.Mass balance

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11. References

1. https://www.acmeplastics.com/what-is-styrene
2. https://www.vaisala.com/en/chemical-industry-solutions/chemicals-allied-
products/styrene-production-process
3. https://www.sciencedirect.com/science/article/abs/pii/S0255270120307273
4. https://www.chemanalyst.com/industry-report/styrene-market-650

5. https://www.mordorintelligence.com/industry-reports/styrene-market

6. https://www.acumenresearchandconsulting.com/styrene-market

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