I/EC
Reports
THE EDITORS ANALYZE A N D INTERPRET THE CHEMICAL WORLD THIS M O N T H
CHLORINE PRODUCTION
Where's the New Chlorine Going? Dynamic CI2 . . . 1956 output: 3.8 million tons. N e w capacity under construction: 1700 t o n s / d a y
I HIRTY
years ago
U.
S.
Production, thousands of short tons Price,$ per ton
industry
produced 550 tons of chlorine per day, which sold for 4 cents a pound. T o d a y it makes 11,000 tons daily, selling for 3 cents per pound. This twentyfold expansion seems astounding even in these days of tremendous industrial growth. What are the reasons behind it? I n 1888, the first liquid chlorine for industry trickled o u t of Germany. By 1909, tank-car shipments became a reality in this country a n d , as the need for paper a n d textile bleaches expanded, the infant industry thrived. T h e year 1920 boosted consumption notably as large-scale chemical uses—spearheaded by chlorination of organic solvents—came into t h e picture. T h e pulp-and-paper industry (historically the biggest single user) was losing ground to chemicals, a n d by 1930 m a d e u p only half of the growing m a r k e t ; by 1937, chemical uses alone h a d exceeded 4 0 % of chlorine sales. At present, this figure is just above 7 5 % , a n d should top 8 0 % by 1960. Chemical Applications I t is startling to realize that chemical uses of chlorine a r e expanding so very rapidly, considering t h e steady growth of paper a n d textiles over t h e past q u a r t e r century. P u l p a n d paper take some 1 5 % of all
chlorine production today. Direct treatment of water a n d sewage— taken for granted so often—uses nearly a q u a r t e r billion pounds of liquid chlorine p e r year; b u t this is just a little more t h a n 3 % of total production. Major chemical applications r e quired the following estimated percentages of chlorine output during 1955: Ethylene oxide a n d glycol Carbon tetrachloride Vinyl chloride Trichloroethylene Tetraethyllead Perchloroethylene Monochlorobenzene Synthetic glycerol
9.1 6.7 5 .4 5.2 5.0 4.5 4.1 3.7
By t h e e n d of last year, production of ethylene oxide h a d approached 100 million pounds p e r m o n t h a n d was d e m a n d i n g 1000 tons of chlorine per day. Even carbon tetrachloride,
a n old staple in the solvent field (over 300 million pounds in 1956), is consuming prodigious quantities of chlorine. I n December (1956) alone, more t h a n 44 million pounds w a s used to make 27.2 million pounds of CC1 4 . An interesting aspect of the chlorine industry is the fact that about 7 0 % of its production is captive. Some of this is chlorine gas for on-site use. Nearly all the merchandised 3 0 % is liquefied (as is most of the captive chlorine), although a little is piped "over the fence" for immediate consumption. Chlorine's Future F u t u r e prospects for the industry are rosy. Hooker Electrochemical has forecast a continuing 8 % a n n u a l growth through 1960. D i a m o n d VOL. 49, NO. 4
·
APRIL 1957
25A
WHERE SOME CHLORINE GOES: For this country's best known p r o d u c t — t o d a y ' s ubiquitous automobile—chlorine is used to make b o d y a n d engine parts, paints, upholstery fabrics, h y d a u l i c - b r a k e fluids, r a d i a t o r antifreezes, spark plugs, lamp filaments, steering wheels, plastic trim, and rubber and cord f o r tires. Furthermore, chlorine plays a vital role in the processing o f lubricants and high-octane gasoline
Alkali economists predict a 50% in crease in chlorine demand between now and 1960—to more than 5 mil lion tons per year. (To help satisfy the expected demand, a 40% expan sion of Diamond's existing chlorine facilities at Deer Park, Tex., is now under way.) And new plants are mushrooming all over the South now: Baton Rouge, La. Brunswick, Ga. Mcintosh, Ala. Memphis, T e n n . Port Neches, Tex.
Dow Kaiser Wyandotte Solvay Olin Mathieson Olin Mathieson D u Pont Jefferson Chemical
Such construction is not entered into lightly—estimated costs for even the larger, more efficient plants ex ceed $100,000 per ton of daily capac ity. Current replacement value of today's facilities amounts to $1.08 billion. At least 1700 tons per day of additional capacity is now under con struction, representing nearly $200 million more. By the time this is all on stream in the fall of 1958, still more building will be under way. By 1960, the production capacity of the chlorine industry may well be valued in excess of $1.5 billion. This pattern of growth is, of course, based upon the growth of the chemical industry as a whole. Four important, fast-developing chemical markets for chlorine are • • • •
A u t o m o t i v e fluids Plastics a n d resins Insecticides a n d herbicides Refrigerants a n d propellants
A diversity of smaller, but some times more vital, applications fills out 26 A
the market: neoprene, chloroorganic chemical intermediates, rocket fuels, pharmaceuticals. The rapid rate of metallurgical de velopment is a really bright promise. The iron and steel industry is hardat work on new chlorine-based proc esses for ore reduction. Most glam orous of all, though, is the new metal lurgy for titanium and zirconium. This in itself may result in astronom ical demands which would render obsolete all existing conceptions of the industry's future.
I/EC
ventured south of the border in search of new markets. Market researchers know this: Mexicans are buying more industrial and agricultural chemicals than ever. The business is going, in large part, to Mexican, American, and Canadian companies. Eager beavers in this country are advising their management to put up plants in Mexico. Technical information is being exchanged right and left with Mexi can companies; U. S. concerns are rapidly forming Mexican subsidi aries. Joint partnerships, too, are increasing. O l d a n d the N e w
The Trek to Mexico Chemical companies, rushing south of the border to build new plants, are ringing up sizable invest ments HE
TREK
TO
MEXICO
IS
ΟΠ,
but
Treason few people know about it. One : Mexican sulfur has hogged a great deal of the publicity (C&EN, Aug. 1, 1955, pp. 3152-4). Nevertheless, chemical invest ments last year alone exceeded several times the number of Ameri can dollars plunged into brimstone properties since 1952. At least a dozen major chemical concerns have
INDUSTRIAL AND ENGINEERING CHEMISTRY
One of the oldest chemical in dustries, naval stores, is being greatly expanded in Mexico. The decision was brought about by availability of good tree stumps. This year Hercules Powder, through acquisi tion of stock in Corbu Industrial, S. Α., will have its first Mexican production of rosin, turpentine, pine oil, and other terpene chemicals. A plant is now under construction in Cruz de Caminos, Michoacan, where raw material is plentiful. Curtailed lumbering operations left many thousands of acres of tree stumps rich in pine resin. There is enough raw material to support a plant having an annual capacity of 25 million pounds of wood naval stores products. Celanese Mexicana, S. Α., an "old-timer" in Mexico, D. F., with seven plants, launched another ex pansion last year aimed at boosting output of acetate fibers and plastics,
I/EC
REPORTS
TREK TO MEXICO: Ocotlan
Entrance to nylon building at Celanese Mexicana plant in
rayon tire cord, cellophane, poly ethylene, and polyvinyl and poly ester resin products. Its new nylon yarn facility recently went on stream and is being increased immediately, tripling production. Less than two months ago, Celanese Mexicana announced it was diversifying into production of formaldehyde resins. T h e company is now building a formaldehyde unit near Mexico, D . F., scheduled for completion this summer. Monsanto Mexicana, S. Α., al ready had a plant at Lecheria, State of Mexico, making various plastics [polystyrene, poly (vinyl chloride), and cellulose acetate], aspirin, and 50 tons of sulfuric acid per day prior to 1956. Now the company is adding a $1.6 million unit to produce sodium tripolyphosphate in Mexico, D. F. No one manufactures this product; last year Mexico pur chased $2 million worth abroad. W h e n Monsanto completes its plant late in 1957, the c o m p a n y expects that the plant will be sufficiently large to supply Mexico's consump tion. This expansion will increase the company's capital investment to a b o u t $4 million. O t h e r companies are moving to
Mexico for the first time. General Mills purchased Protex, S. Α., of Mexico, D. F., in 1956. Protex produces steroid compounds used to manufacture cortisone and other steroidal hormones. T h e acquisi tion marked General Mills's third business venture outside the U . S. and the company's first move into Latin America. General Mills offi cials said they will continue to make steroid intermediates at Kankakee, 111. Protex products differ chemi cally from those already manufac tured by General Mills; the move strengthened a n d broadened the company's position as a supplier to the pharmaceutical industry. Cyanamid, too, went the phar maceutical route last year in a big way. (It had been operating in Mexico since 1938 through a sales office established by Laboratories Lederle de Mexico, S. A.) Business got big enough in 1949 to support warehouse facilities a n d last year American Cyanamid completed a manufacturing plant near Mexico, D. F., that turns out Achromycin tetracycline, Aureomycin chlortetracycline, and other Lederle p h a r m a ceutical products. Cutter Laboratories, which has
distributed in Mexico since 1923, will have a veterinary pharmaceuti cal plant in operation by mid-1957. T h e plant is a joint venture with Mexican interests. Cutter officials describe Cutter Laboratories de Mexico as the first step in the company's plan to eventually pro duce a full line of veterinary phar maceuticals a n d biologicals for the Mexican market. Pennsalt International Corp., an other pioneer in Mexico, has orga nized its third subsidiary—Industrial Quimica Pennsalt—which will begin manufacture of chlorine and caustic soda by mid-1957. Existing opera tions include Pennsalt de Mexico, producer of calcium arsenate, in secticides, and other chemical special ties in Mexico, D. F., a n d Minérales y Metales Industriales, operating Mexico's largest metallurgical grade fluorspar mine near San Luis Potosi. Montrose Mexicana, S. Α., was organized last year to construct a mercury cell chlorine-caustic soda plant near I r a p a u t o . It will also put u p units to manufacture monochlorobenzene, chloral, and D D T . T h e new enterprise, managed by Montrose Chemical, received a $2 million loan from a French b a n k ; another $2 million came from Ameri can and Mexican sources. Instrument manufacturers, too, see the potential of Mexican markets. Fischer & Porter de Mexico, S. Α., established in late 1953, now has a head office in Mexico City a n d a branch in Monterrey, with a com bined staff of five engineers. T h e company does not expect overnight returns from the Mexican invest ment, but takes a long-range view, with optimism a n d realization of Mexican potential for instrument sales, especially in the local petro leum industry. Last year Fischer & Porter sent a demonstration trailer south of the border to exhibit process instruments. It contained a fully instrumented, graphic, con trol panel a n d chlorination equip ment. T h e trailer went to chemical plants, oil refineries, food processing plants, paper mills, and other estab lishments, including water, sewage, gas, a n d power plants. Fischer & Porter put on a demonstration for management, engineering, and in strument maintenance personnel in numerous cities.
VOL. 49, NO. 4
·
APRIL 1957
29 A
I/EC
HILLS-
REPORTS
Partnerships Grow Rapidly
McCANNAMETER meters and pumps with unfailing accuracy A packless, positive displacement pump, the Hills-McCannameter operates on an entirely new pumping principle to create a new high in metering accuracy, a new low in oper ating costs. Maintenance simplified through unique capsulated construction. Perfect for laboratory and production proportioning of low viscosity fluids over extended time peri ods. Send for in formative booklet "The Meter T h a t Pumps."
Late in December Dow Chemical bought a 50% interest in Productos Quimicas Mexicano, S. Α., producer of chlorine and caustic soda. This firm, which also makes bleaching powder, bleaching liquor, and chlo rates, owns the largest electrolytic plant in Mexico, D. F. It's a 20year-old concern, half-owned by Mexican citizens. Productos Qui micas plans to double plant output as soon as possible. Heyden Chemical purchased a chunk (one third) of Salicilatos de Mexico, located in Mexico, D. F. By mid-year the company started Mexico's first salicylic acid produc tion, enough to supply domestic requirements with a surplus for export. Early last year Scott Paper ac quired a substantial financial and voting interest in Cia. Industrial de San Cristobal. New capital will be used to expand pulp production capacity, complete a new bleach plant, and improve paper-making facilities. Branch Offices Pop Up
DIAPHRAGM VALVES with the exclusive Hills-McCanna Sealing B e a d D i a p h r a g m
Hills-McCanna Diaphragm Valves are available in a variety of materials to offer positive control for all gas, liquid and corrosive services. Features sim plified, maintenance-free construction. Write for 12 page Valve booklet. Hills-McCanna Company 2345 W. Nelson Ave., Chicago 18, Illinois
For further information, circle number 30 A on Readers' Service Card, page 129 A 30 A
INDUSTRIAL A N D ENGINEERING
CHEMISTRY
Sales offices, for companies which haven't decided yet to manufacture products south of the border, are becoming popular. Allied Chemical & Dye recently established a Mexi can branch at Mexico, D. F., to develop markets for its products. Another newcomer in Mexico, D. F., Columbia Carbon Internacional dc Mexico, will handle sales of carbon blacks and iron oxides plus materials for the rubber, paint, ink, plastics, paper, and synthetic fiber industries. Another popular trend is afoot— exchange of technical information. Last year Catalin Corp. agreed to swap know-how with Adhesivos Résistai, S. Α., for a 5-year period. Catalin will pass along information on the production of phenolic, cresylic, resorcinol, melamine, and urea liquid resins; it will get similar information from Adhesivos Résistai, Mexican producer of industrial adhesives. All factors considered, the future of the chemical industry in Mexico is bright indeed. Industry is expanding and the demand for basic chemicals should continue strong for the long pull.
DIATOMITE FOR NON FILTERAID USES
The versatility of diatomite products is exhibited to a remarkable degree in the non-filteraid uses. A comprehensive review of these applications would fill a book —hence, only a few highlights here. CHEMICAL PROPERTIES. In many of its applications as a filler, diatomite is chosen because of its inertness. The calcined and flux calcined grades are outstanding in this respect. In most compositions these grades exhibit no solubility or adsorption whatsoever. On the other hand, non-calcined (natural) diatomite is extremely reactive, particularly to alkalis. While no fundamental studies on specific reaction rates have been reported in the -literature, considerable work has been conducted in industrial laboratories. These experiments have shown that natural diatomite is intermediate in reactivity between crystalline forms of silica and silica g e l . . . this follows, of course, from the fact that natural diatomite is hydrous silica. Natural diatomite has tremendous surface area in proportion to weight; that from certain deposits has nitrogen adsorption surface areas exceeding 35 square meters per gram. Thus, the diatomite industry provides a naturally-occurring mineral, in a variety of carefully controlled grades, priced in the range of other non-metallic minerals, which has the characteristics of manufactured products, such as silica gel, which cost several times as much. Several uses have been made of this property of natural diatomite. For example, the high reactivity of diatomite to alkali has been used to control deleterious effects occurring when high alkali Portland cements are combined with reactive aggregates. No known naturally-occurring material reacts more rapidly with free alkali in cement slurries than does diatomite. The insulation industry uses a large tonnage of diatomite to produce precast and other forms of thermal insulation by the reaction of hydrated lime and diatomite. This reaction, suitably catalyzed, is so fast that solid gels may be formed by heating to 175° F. for one minute. This permits rapid stripping from the molds to hold production costs in line. Such fast reaction presents profitable possibilities in the production of other lightweight products in the range of 5-25 pounds per cubic foot. (ADVERTISEMENT)
Paul W. Leppla Technical Director
4 CALCINED
/Shite ot 1 * * ·
dteC
Since Dicalite is essentially hydrated amorphous silica, it is i n e r t . . . we've stressed the point for years. But it might be noted that there is an exception. The natural grades of Dicalite (meaning not calcined or flux-calcined) are extremely reactive with alkalis, a property made use of in the cement and insulating fields, and one which should be of value if you are concerned with certain types of lightweight materials, or processes requiring solid gels. In the vast majority of applications, though, Dicalite 'filler' materials are completely inert, for all practical purposes. Furthermore, the unique characteristics given by the shape and structure of the diatomite particles provide several other desirable properties . . . great bulk in relation to weight, which gives bulking without significant increase in weight... tremendous surface area in relation to weight... extreme porosity, making Dicalite highly absorptive and also lending both heat-and-electrical resistance. These are the principal values of Dicalite filler materials; there are others. Dicalite's engineering service will be glad to advise with you on your particular problem, or you may obtain additional information by writing :
icalite
Dependable
®
GLC GREAT
LAKES
DIATOMACEOUS
MATERIALS
DICALITE DIVISION/GREAT LAKES CARBON CORP./612 S. FLOWER ST./LOS ANGELES I T
For further information, circle number 31 A on Readers' Service Card, page 129 A
VOL. 49, NO. 4
·
APRIL 1957
31 A
I/ΕC
N I A G A R A SECTIONAL A e r o HEAT E X C H A N G E R gives close temperature control, saves you LABOR, Power, Water •
Because the n e w design improves the heat transfer to the out-door air by e v a p o r a t i o n .
•
Because n e w features keep your e q u i p m e n t w o r k i n g for l o n g life with " n e w p l a n t " e f f i c i e n c y . . . a l w a y s full capacity.
•
Because y o u save 9 5 % of cooling w a t e r cost.
You get faster, more accurate cooling of industrial fluids to specified temperatures. You improve your quality of production by removing heat at the rate of input. You save labor in upkeep. W i t h full access to all interior parts and piping you see everything in easy inspections. You head off dirt accumu lation and corrosion. Casing panels are removable -without moving the coils. The coils can be cleaned from both sides. First cost is low; freight is low because of the lowest space/weight ratio; you save much labor in erection. Capacity range is 7,000,000 to 18,000,000 Btu/hr. N o other heat exchange method gives you so much saving in money and convenience. Write for Niagara Bulletin 132. Ask for the full story of how you can save expense in your plant and improve your product's quality.
N I A G A R A BLOWER COMPANY Dept. EC-4, 4 0 5 Lexington Avenue N E W Y O R K 17, Ν . Υ. Districf
Engineers
NIAGRA
in
Principal
Cities
Over 40 Years'Service in Industrial
Air Engineering
For further information, circle number 32 A on Readers' Service Card, page 129 A 32 A
INDUSTRIAL AND ENGINEERING CHEMISTRY
REPORTS
Many companies are moving south of the border because technical and sales service requirements of cus tomers there are becoming too great for agents to handle. Companies save on Mexican exchange, employ local personnel, and are accepted in to the market more readily when they own plants in Mexico. Some con cerns, fearing that new tariffs will make export of U. S. products less attractive, are hedging with Mexican production. Profit margins compare favorably with those in the U. S. and Canada, although they are somewhat lower. Mexico's rate of growth and low priced foreign competition seem to be the biggest factors holding people back. This year and the next, however, should bring an increasing number of Mexican-American partnerships— a trend that is currently popular.
I/EC
Chemistry's 4th Dimension — Radiation Many applications are in sight —now we must de velop radiation sources with higher output at lower cost EAT, pressure, and catalysts have H long been the three major means of directing and controlling chemical reactions. Now the atomic age is adding a fourth dimension—nu clear radiation. Many problems still remain unsolved, but the prom ising results obtained thus far are a good indication that radiation will be an integral part of many future chemical reactions. The variety of materials and proc esses to which radiation can be adopted seems almost endless. Ir radiated polyethylene is probably the best known, although the list of current research activities stretches
