A NATIONAL HISTORIC CHEMICAL LANDMARK
CHEMICALS FROM COAL FACILITY EASTMAN CHEMICAL COMPANY KINGSPORT, TENNESSEE NOVEMBER 6, 1995
A M E R I C A N
C H E M I C A L
SOCIETY
Division of the History of Chemistry and The Office of Public Outreach
T
his b o o k l e t c o m m e m o r a t e s t h e designation of the Chemicals from Coal Facility of Eastman
C h e m i c a l C o m p a n y as a N a t i o n a l H i s t o r i c Chemical L a n d m a r k . T h e designation was c o n f e r r e d b y t h e A m e r i c a n C h e m i c a l Society, a n o n - p r o f i t s c i e n t i f i c a n d educational organization of 1 5 0 , 0 0 0 chemists a n d c h e m i c a l engineers. T h e Chemicals from Coal Facility is l o c a t e d i n K i n g s p o r t , Tennessee o n a 5 5 - a c r e site a d j o i n i n g Eastman's e x i s t i n g c h e m i c a l c o m p l e x . T h e f a c i l i t y began o p e r a t i o n i n 1 9 8 3 after t h r e e years o f c o n s t r u c t i o n a n d m o r e t h a n e i g h t years of w o r k t o i d e n t i f y , develop, a n d assemble t h e technologies necessary t o m a k e t h e operation viable. A plaque m a r k i n g t h e A C S d e s i g n a t i o n was presented at t h e f a c i l i t y o n N o v e m b e r 6, 1 9 9 5 . T h e i n s c r i p t i o n reads: " T h i s p l a n t was t h e f i r s t i n t h e U n i t e d States t o use coal r a t h e r t h a n p e t r o l e u m as a r a w m a t e r i a l i n t h e c o m mercial production of acetyl chemicals— i m p o r t a n t b u i l d i n g b l o c k s i n t h e synthesis o f a w i d e range of c o n s u m e r p r o d u c t s , i n c l u d i n g plastics, t e x t i l e f i b e r s , a n d
ACKNOWLEDGMENTS
p h o t o g r a p h i c f i l m . T h e p l a n t came o n
The American Chemical Society gratefully acknowledges the assistance of the scientists and historians who helped prepare this booklet, including: David J. Allen, Edward U . Elam, Elizabeth M . West, Northeast Tennessee Section of the American Chemical Society; Nancy K. Ledford, Paul W. Montgomery, Michael O. O'Neill, Donald J. Shields, William L . Trapp, Eastman Chemical Company; Jeffrey L . Sturchio, Merck & Co., Inc.; and A n n C. Higgins, American Chemical Society. This booklet was produced and printed by the Eastman Chemical Company Printing and Visuals Department. Writers: David J. Allen, Donald J. Shields, Jane Meade-Dean. Design: Linda Medlin. Photographic Services: Patrick K Cagney. Photographs courtesy of Eastman Chemical Company. ACS Production Liaison: Vivian Powers.
s t r e a m i n 1 9 8 3 , f o l l o w i n g e i g h t years o f research a n d process d e v e l o p m e n t i n coal g a s i f i c a t i o n a n d related t e c h n o l o g y p r o m p t e d b y t h e o i l embargoes o f t h e 1970s. A n expansion project i n 1 9 9 1 d o u b l e d t h e o r i g i n a l capacity. B y s u b s t i t u t i n g l o c a l l y available, h i g h - s u l f u r c o a l , t h i s process conserves the e q u i v a l e n t o f 1.5 m i l l i o n barrels o f o i l per year p r e v i o u s l y r e q u i r e d f o r t h e p r o d u c t i o n o f these high-volume chemicals."
Copyright © 1995 American Chemical Society
The Bounty of Coal
F;
lor centuries, people have been making
Most recently, coal gasification technologies
useful products by performing chemical
like those used by Eastman have been employed to
reactions w i t h natural substances—every-
produce chemical feedstocks, the building blocks from
t h i n g from manufacturing glass from sand to converting
w h i c h complex chemicals like plastics, fibers, dyes, and
wood t o methanol, acetic acid, and charcoal. T h r o u g h -
other consumer products are constructed. Eastman is the
out the years, coal has been an important natural
first company i n the U . S . to produce a new generation
resource i n the manufacture o f chemical products.
of industrial chemicals commercially using coal gasifica-
Liquid coal tar products were first obtained from coal i n England during the 1700s and used i n ship-
t i o n technology. D u r i n g the 1930s, coal was used as a principal
building. Lamp o i l was produced from coal i n the U . S .
raw material i n the production o f 60 percent o f organic
as early as 1850. I n the late 1800s, fuel gas and metal-
materials, while petroleum was used i n only 10 percent.
lurgical coke were made i n Germany. T h e resulting tar
By 1960, the proportions were reversed. Due t o the
by-products were refined and used around the world as
availability o f vast new supplies o f crude petroleum and
aromatics for pharmaceuticals, dyes, explosives, and
the i n t r o d u c t i o n o f improved refining techniques,
photographic chemicals. A s a result o f W o r l d War I
petroleum and natural gas n o w supplied more t h a n 80
and Germany's embargo o f aromatic coal tar products—
percent o f all industrial organic chemicals, while coal
particularly toluene needed for T N T — t h e U . S . domestic
was the source o f only 20 percent o f organic materials.
coal-chemicals industry developed. Throughout the 2 0 t h century, coal was
I n 1973, a boycott by A r a b members o f the Organization o f Petroleum Exporting Countries ( O P E C )
converted to gases or liquids, w h i c h typically were
triggered petroleum shortages i n the U . S . and a surge i n
reacted w i t h carbon monoxide i n the presence o f
the price o f crude o i l from $3 to $30 a barrel. W h i l e the
catalysts to form
A m e r i c a n public endured
methanol or related
long lines at the gas
simple molecules. T h e
pumps, the chemical
coal gases or liquids could
industry's production
also be cracked to give
of industrial organic
olefins and acetylenes,
chemicals was hampered.
w h i c h were t h e n used
Acetic Anhydride from Coal Flow
I:
n the years leading up to the o i l embargo, the chemical process industries expanded
. their energy conservation programs and
—
began a search for lower-cost chemical feedstocks. I n
Coal Mixed with Water in a Slurry
1970, Eastman scientists conducted a prescient p l a n n i n g study that considered solutions for a critical set of
Heat Recovery Unit 7
O2
Reacts with s Oxygen Under Pressure
circumstances. T h e company was heavily dependent o n petroleum and natural gas as raw materials for the manufacture o f key chemicals, particularly acetic anhydride. T h e supply o f o i l worldwide, especially i n the U.S., was
= C O , CO2 H2S, H2
finite and rapidly diminishing. Based o n its intrinsic
Shift Reactor CO+H>0= Hi + C 0 2 j
value, p e t r o l e u m — w h i c h was t h e n selling for only a few dollars a barrel—was significantly underpriced. T h e cost of o i l would increase and, given certain circumstances,
Water Bath \
Scrubber Removes Ash & Slag
could skyrocket drastically. T h e 1970 study projected that coal would become a more attractive energy source t h a n o i l and an important chemical feedstock. Located i n the heart of the A p p a l a c h i a n coalfields, the company was i n a unique position to utilize this abundant, economical resource. T h e events of 1973 caused Eastman to
gas i n a specific carbon monoxide-to-hydrogen ratio. A
recognize the immediate need for a commercially
p o r t i o n of the gas from the gasifier is sent to a "shift"
feasible means o f synthesizing critical high-volume
reactor to increase the hydrogen content.
chemicals such as acetic anhydride from raw materials
T h e two product gas streams from the gasifier—
other t h a n petroleum. A c e t i c anhydride, at the time
the shifted gas and the raw synthesis gas—are purified
derived from petroleum feedstocks, had earlier been
i n a number of steps. T h e hydrogen sulfide and carbon
identified as a key product Eastman could produce using
dioxide are removed using the Linde A G Rectisol
coal. Eastman consumes more than one b i l l i o n pounds
process. T h e hydrogen sulfide is converted to elemental
of acetic anhydride annually i n cellulosic plastics, filter
sulfur using a Claus process followed by a Shell Claus
products, textile yarns, and i n the production of photo-
off-gas treating u n i t , resulting i n 99.7 percent o f the sul-
graphic f i l m . A c t i v e research and development o n a
fur originally i n the coal being recovered and sold as a
coal-based anhydride process, initiated i n 1975, eventu-
co-product of the operation. Carbon dioxide is also
ally involved several hundred employees from several
recovered and sold to make carbonated beverages. T h e
departments. T h e first small p i l o t plants began operation
purified raw synthesis gas stream is t h e n sent to a "cold
i n 1977.
box" and cryogenically separated i n t o hydrogen and T h e Texaco C o a l Gasification Process was
carbon monoxide using Linde A G technology. T h e
selected to be the source of synthesis gas, a c o m b i n a t i o n
hydrogen is mixed w i t h the shifted gas and sent to the
of carbon monoxide and hydrogen that is suitable for
methanol plant, and the carbon monoxide is used for
conversion i n t o more complex chemicals. T h e process
acetic anhydride production.
was specifically designed to use coal from the nearby
M e t h a n o l is produced using a catalytic gas-
Virginia coalfields. Oxygen and a coal/water slurry are
phase reactor developed by Lurgi A G . T h e proper gas
introduced i n t o the gasifier under conditions o f h i g h
feed composition for methanol production is obtained
temperature and pressure, w h i c h produces the synthesis
by c o m b i n i n g the hydrogen-enriched gas from the shift
An Idea Becomes a Reality f r o m
C o a l
F a c i l i t y Before construction o f the actual facility could
Steam
Acid Gas Removal Plant
begin, the 55-acre site had to be elevated above the 100-year floodplain of the H o l s t o n River. M o r e t h a n 500,000 cubic yards of f i l l d i r t were used to raise the area where the facility would stand. Carbon Monoxide and Hydrogen Separator
Construction began i n July 1980 and continued for nearly three years, w i t h more t h a n 2,600 workers employed at the peak of the building project. T h e original facility required more t h a n 6,000 tons of
CO + - ;,H2
structural steel, 27,000 cubic yards o f concrete, 1 m i l l i o n feet o f pipe and conduit, and 10,000 miles o f electrical
^Reaction I ^eth, Produces A ? J . . \ Methyl W A c e t i c A c i d to Alcohol Z. Methyl e
a
t
e
d
w
l
CO
h
A
f
o
r
m
and instrument wire. C o a l grinding and slurry operations began i n M a r c h 1983, and the m e t h y l acetate plant started i n May. T h e first o f two gasifiers was fired o n June 19, and methanol production began one m o n t h later. A c e t i c anhydride production began o n October 6, 1983, and the desired product quality was achieved almost immedi-
Acetic Anhydride!
ately. During the first nine months of operation, the gasifiers operated more t h a n 85 percent o f the time, and the acetic anhydride and m e t h y l acetate units operated
reactor w i t h the hydrogen gas stream from the gas separation unit. Using a reactive distillation process developed
more t h a n 75 percent o f the time. D u r i n g a scheduled maintenance shutdown i n July of the following year, several process improvements
at Eastman, methanol made from the synthesis gas reacts
identified during the i n i t i a l operation were implement-
w i t h acetic acid, a co-product from cellulose esters
ed. Since that time, additional improvements have
manufacturing, to form m e t h y l acetate. I n the final step,
enabled the facility to produce acetic anhydride more
w h i c h uses an Eastman proprietary catalyst system and
t h a n 97 percent o f the time.
process, purified carbon monoxide from the gas separation plant reacts w i t h m e t h y l acetate to form acetic anhydride. M e t h a n o l is also added to the anhydride process to coproduce acetic acid. T h e development o f the acetic anhydride reactor configuration was the m a i n engineering issue i n the process development. Two pilot plants were constructed and operated w i t h several reactor designs to evaluate competing schemes. Designs for evaporators, vacuum distillation columns, and control schemes were based o n computer simulations w i t h some assistance from p i l o t plant testing.
A Regional and Environmental Asset T h e energy efficient, environmentally responsible Chemicals from Coal Facility gasifies about 1,150 tons of high-sulfur coal per day produced from nearby Virginia mines. T h i s conserves the equivalent of some 1.5 m i l l i o n barrels of o i l annually. I n addition, the facility recovers 99.7 percent of the sulfur contained i n the coal for sale to the sulfuric acid industry. Carbon dioxide generated from the gasification process is also collected, treated, and sold for use i n carbonated beverages. T h e facility doubled i n size after an expansion was completed i n 1991 and currently employs about
sludge, and used tires and oils to produce electrical
300 people.
power and chemicals. U s i n g the knowledge gained from
The Future
o n a new and more economical carbonylation route to
the existing complex, Eastman researchers are working
T h e Chemicals from Coal Facility makes Eastman the first U . S . manufacturer to produce a modern generation of industrial chemicals from coal. T h e project has resulted i n new methods for engineering design, new materials for high-temperature applications,
new building-block chemicals from coal.
Eastman Chemical Company Eastman C h e m i c a l Company traces its begin-
and new mechanical maintenance methods. More
nings to the early 1900s w h e n George Eastman was
importantly, the innovative process provides potential
searching for a methanol supplier for the cellulose
routes for using synthesis gas to produce other chemicals
acetate-based photographic chemicals that were central
from coal, further reducing U . S . dependency o n foreign
to Eastman Kodak Company's business. Kodak's depen-
petroleum.
dence o n European suppliers had become all too appar-
Today, coal gasification can be used to gasify
ent during W o r l d War I , and Eastman was determined to
not only the conventional feedstocks, but also various
find an alternative. I n Kingsport, Tennessee, he found an
wastes such as asphaltenes, petroleum coke, sewage
abandoned wood-distillation plant originally established to supply methanol and other chemicals for the federal government. T h e abundance of trees i n this area assured Eastman o f a ready supply of raw materials, and he purchased the vacant plant i n 1920. Five decades later, the same business strategy that led Eastman to make Kodak independent of European sources of the chemicals critical to his photographic process motivated Eastman Chemical Company to begin research i n t o chemicals from coal. Eastman Chemical Company operated as a division o f Kodak for 73 years before becoming an independent, publicly owned company o n January 1, 1994-
REFERENCES FOR FURTHER READING Fred Aftalion. A History of the International Chemical Industry. [Translated by Patrick P. McCurdy]. Philadelphia: University of Pennsylvania Press, 1991.
S. W. Polichnowski. "Transition-Metal-Catalyzed Carbonylation of Methyl Acetate." Journal of Chemical Education 63 (1986): 206-209.
Victor H . Agreda. "Acetic Anhydride from Coal." C H E M T E C H 18 (April 1988): 250-253.
H. Harry Szmant. Organic Building Blocks of the Chemical Industry. New York: John Wiley & Sons, 1989.
Victor H . Agreda, Lee R. Partin, William H . Heise. "HighPurity Methyl Acetate via Reactive Distillation." Chemical Engineering Progress (February 1990): 40-46.
Arnold Thackray, Jeffrey L. Sturchio, P. Thomas Carroll, Robert Bud. Chemistry in America, 1876-1976: Historical Indicators. Dordrecht: D. Reidel Publishing Company, 1985.
Victor H . Agreda, David M. Pond, Joseph R. Zoeller. "From Coal to Acetic Anhydride." C H E M T E C H 22 (March 1992): 172-181.
Klaus Weissermel, Hans-Jiirgen Arpe. Industrial Organic Chemistry. [Translated by Alexander Mullen]. Weinhein: Verlag Chemie, 1978.
Victor H . Agreda and Joseph R. Zoeller, eds. Acetic Acid and Its Derivatives. New York: Marcel Dekker, 1993.
J. E. Wolff, David M . Pond. "Chemistry in a Petroleumless World." McGrau'-Hil! Yearbook of Science and Technology. New York: McGraw-Hill Book Company, 1982: 37-43.
"1985 Kirkpatrick Chemical Engineering Achievement Award, Winner: Tennessee Eastman." Chemical Engineering (December 9/23, 1985): 79-81.
Paul R. Worsham. "Feedstocks." Kirk-Othmer Encyclopedia of Chemical Technology 10 (1994): 325-349.
G. G. Mayfield, V. H . Agreda. "The Eastman Chemical Process for Acetic Anhydride From Coal." Energy Progress 6 (1986): 214-218.
Joseph R. Zoeller, Victor H . Agreda, Steven L. Cook, Norma L. Lafferty, Stanley W. Polichnowski, David M . Pond. "Eastman Chemical Company Acetic Anhydride Process." Catalysis Today 13 (1992): 73-91.
THE NATIONAL HISTORIC CHEMICAL LANDMARKS PROGRAM OF THE AMERICAN CHEMICAL SOCIETY T h e A C S N a t i o n a l Historic Chemical Landmarks Program recognizes our scientific and technical heritage and encourages the preserv a t i o n of historically important achievements and artifacts i n chemistry, chemical engineering, and the chemical process industries. I t provides an annotated roster to remind chemists, chemical engineers, students, educators, historians, and travelers of an inspiring heritage that illuminates
NATIONAL HISTORIC CHEMICAL LANDMARK
CHEMICALS FROM COAL FACILITY stman Chemical Company ogsport, Tennessee
b o t h where we have been and where we m i g h t go w h e n traveling the diverse paths to discovery. An
A C S Historic Chemical Milestone designation marks a
landmark step i n the e v o l u t i o n of the chemical sciences and technologies. A Site designation marks the location of an artifact, event, or other development of clear historical importance to chemists and chemical engineers. A n Historic C o l l e c t i o n designation marks the contributions o f a number of objects w i t h special significance to the historical development o f chemistry and chemical engineering. T h i s program began i n 1992 w h e n the D i v i s i o n of the History o f Chemistry and the A C S formed an international Advisory Committee. T h e Committee, composed of chemists, chemical engineers, and historians o f science and technology, works w i t h the A C S Office of Public Outreach and is assisted by the Chemical Heritage Foundation. Together, these organizations provide a public service by examining, noting, recording, and acknowledging
particularly significant achievements i n chemistry and chemical engineering. For further information, please
contact the A C S Office of Public Outreach, 1155 Sixteenth Street, N W , Washington, D . C . 20036, 800-ACS-5558, Press 954.
T h e A m e r i c a n C h e m i c a l Society
Eastman Chemicals from Coal Historic
B r i a n M . R u s h t o n , President
Designation Planning Committee
R o n a l d C . Breslow, P r e s i d e n t - E l e c t
Paul W . M o n t g o m e r y , C h a i r m a n
Paul H . L . Walter, Board C h a i r m a n
D a v i d J. A l l e n
John K C r u m , Executive Director
T r a c y K . Bledsoe
A n n B . Messmore, Director, Public O u t r e a c h
P a t r i c k F. C a g n e y Jan G . K a s t e n
A C S D i v i s i o n of the H i s t o r y of Chemistry
N a n c y K . Ledford
M a r t i n D . Saltzman, C h a i r m a n
Linda C. Medlin
Joseph B . L a m b e r t , C h a i r m a n - E l e c t
Steven T. Perri
V e r a V . M a i n z , Secretary-Treasurer
D o n a l d J. S h i e l d s
R i c h a r d E. R i c e , P r o g r a m C h a i r m a n
Patricia C . S u t t o n Elizabeth M . West
N o r t h e a s t Tennessee A C S Section S t e v e n T. P e r r i , C h a i r m a n
A C S Advisory Committee on National Historic
J o h n K . Sanders, C h a i r m a n - E l e c t
Chemical Landmarks
R e n e e E. N i z i u r s k i - M a n n , Secretary
C h a i r m a n : Jeffrey L . S t u r c h i o , M e r c k & C o . , I n c .
C h e r y l A . M o r g a n , Treasurer
James J. B o h n i n g , A m e r i c a n C h e m i c a l S o c i e t y Jon B. Eklund, N a t i o n a l Museum of A m e r i c a n
N o r t h e a s t Tennessee A C S Section H i s t o r i c a l Site C o m m i t t e e Edward U . Elam, C h a i r m a n D a v i d J. A l l e n R o b e r t J. M a l e s k i George G . Mayfield Steven T. Perri
History Yasu F u r u k a w a , T o k y o D e n k i U n i v e r s i t y Leon Gortler, Brooklyn College Ned D. Heindel, Lehigh University P a u l R . Jones, U n i v e r s i t y o f N e w H a m p s h i r e James W L o n g , U n i v e r s i t y o f O r e g o n Peter J. T . M o r r i s , N a t i o n a l M u s e u m o f S c i e n c e and Industry, L o n d o n M a r y Jo N y e , O r e g o n S t a t e U n i v e r s i t y S t a n l e y I . Proctor, P r o c t o r C o n s u l t i n g Services D a v i d J. Rhees, B a k k e n L i b r a r y a n d M u s e u m A n n C . Higgins, A C S Staff L i a i s o n
American Chemical Society 1155 Sixteenth Street, N . W . Washington, D . C . 20036
