notes, the current incentive to substitute polyacetal for other materials is so strong that commercialization time has decreased from an average of two years to 18 months. Du Pont's Mr. Nelson agrees that new applications for polyacetal have a relatively long incubation period. Although he sees this lag as an advantage in planning new capacity, he cautions that it creates a hazard, especially in the current competitive price situation. Du Pont is avoiding substitutions for polyacetal that might evaporate later if prices of the competing materials come down again. However, Mr. Stemmler thinks that competing materials' prices never will drop back to the levels prior to 1973. On a cost-per-cubic-inch basis, polyacetal has gained an enormous advantage, as large as 10 to one, over
Naphthalene feedstock outlook mixed
This year is shaping up as a good one To achieve this, phthalic producers for producers of naphthalene from coal will have to operate at an average of tar but a poor one for producers who 93% of capacity. Present phthalic cause petrochemical feedstocks. For pacity is an estimated 1.125 billion naphthalene consumers, however, the pounds a year, with 715 million pounds net result is a tight supply that will based on o-xylene. The switch from keep them scratching for material. naphthalene to o-xylene as the preThe typical petronaphthalene pro- ferred phthalic feedstock has been draducer is much like Casey at the bat matic. In the past few years, four large this year. Both are coming up in a winning situation: Casey with men on base plants—in the 100 to 130 million range—have been and the petronaphthalene producer pound-per-year with sharply higher prices to boost brought on stream based on o-xylene. profits. Both have the capability; Meanwhile, several old naphthaleneCasey is a slugger and petronaph- based units have been shut down bethalene producers have more than cause they were not competitive. Now, only two phthalic plants are operating enough plant capacity. But, like mighty Casey, the petro- on petronaphthalene feed and only two naphthalene producers have struck out. others are using coal tar naphthalene. Union Carbide and Monsanto operThe first strike against petronaphthalene is that its major use is in making ate the two remaining phthalic units Polyacetal cost compares phthalic anhydride and phthalic pro- that still use petronaphthalene. Both duction will grow little if at all this Carbide's plant at Institute, W.Va., and favorably with competitors year. The second strike is that petro- Monsanto's at Bridgeport, N.J., are old Cents Cents naphthalene (along with coat tar naph- units with a rated capacity of 85 milper Specific per thalene) has to compete against o-xy- lion pounds per year. Carbide, in fact, pound gravity c u . i n . lene as a feedstock for phthalic. This considered shutting down its plant but Modified polyyear, almost 65% of phthalic output decided to keep it operating because 3.0 75 1.1 phenylene oxide will be derived from o-xylene. The phthalic supply was tight. If the third strike against petronaphthalene phthalic squeeze eases up, it is a good 1.4 3.1 60 Polyacetal producers is that they can barely bet that Carbide will go ahead with its 59 1.8 Magnesium 3.8 scrape together enough feedstock to plans to shut down the unit. 95 1.3 Polycarbonate 4.3 handle even their dwindling share of These two petronaphthalene-based Thermoplastic the phthalic market. phthalic units will probably produce 1.5 4.4 80 polyester Phthalic anhydride accounts for 72% about 150 million pounds of product 1.4 4.9 98 Nylon of total naphthalene consumption. this year, consuming 160 million Phthalic itself is tight this year. Out- pounds or more of petronaphthalene 51 5.0 2.7 Aluminuma put through the first four months was feedstock. The four petronaphthalene 39 9.2 Zinca 9.3 341 million pounds, according to Tariff producers have 450 million pounds of Copper 81 8.9 26 Commission figures. This is only 3% annual capacity but will produce only 101 Brass 32 higher than output during the first four about 190 million pounds this year. months of last year and actually less That is all that the tight feedstock sita Die-cast alloy. than production during the final four uation will allow. Monsanto, the only months of 1973. Last year, phthalic captive producer, also has captive competitive nonferrous metals. The po- producers turned out 1.027 billion naphthalene feedstock from Chocolate tential substitution market here is pounds of product. This year, they Bayou, Tex., and its 100 million more than 500 million pounds per year, probably will produce no more than pound-a-year naphthalene unit at Mr. Stemmler estimates, with die-cast 1.050 billion pounds. Alvin, Tex., would be able to crank out aluminum the prime target. Steeply rising prices for ceramic parts may open up new polyacetal markets in Naphthalene: more from coal tar than from petroleum areas such as plumbing fixtures. Both Celanese and Du Pont are find- C o m p a n y Capacity Feedstock Location ( m i l l i o n s of p o u n d s per y e a r ) ing plumbing a rich market for polyacetal. Celanese calls it the fastest Allied Chemical Ironton, Ohio Coal tar 55 growing polyacetal outlet by far. PolyDetroit, Mich. acetal has the biggest share of engineer- Ashland Oil Catlettsburg, Ky. Petroleum 100 ing plastics' penetration in this field, Getty-Collier Petroleum Delaware City, Del. 100 knocking brass, especially, out of an increasing number of applications. Koppers Follansbee, W.Va. 190 Coal tar Chicago, III. In plumbing, automobiles, and its other major markets—appliances, elec- Monsanto Alvin, Tex. Petroleum 100 trical and electronic equipment, and Sun Oil Petroleum Toledo, Ohio 150 machinery—polyacetal is prospering in Coal tar U.S. Steel Clairton, Pa. 200 the number three position (after polyFairfield, Ala. carbonate and nylon) in the more than Gary, Ind. 500 million pound-per-year engineering Fairless, Pa. thermoplastics market. Compared to 25 Coal tar predictions just two or three years ago Other that polyacetal would be increasingly vulnerable to inroads from materials 470 Total coal tar such as thermoplastic polyester, polyacetal's current position represents a 450 Total petroleum strong turnaround. GRAND TOTAL
m
14
C&EN July 8, 1974
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Name, Company , Address City.
I I ^Sik I m 1»
- State.
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-ZipDivision of Kewanee Oil Co. 1945 East 97th Street Cleveland, Ohio 44106 Telephone (216) 721-8300
. . . and most of it will be made from o-xylene
Phthalic anhydride output will grow little this year... 1100
Production, millions of pounds
1000
Feedstock
900
Phthalic Phthalic anhydride anhydride produccapacity 1 tion1 ( m i l l i o n s of p o u n d s per y e a r )
Coal tar naphthalene Petronaphthaiene o-Xylene rOTAL
800 700. 600
240 170 715 1125
220 150 680 1050
a 1974 d a t a .
0 1965
66
67
68
69
70
71
72
73. j
a C&EN estimate. Source: Tariff Commission
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