Phenol: A Statistical Review JOHN R. SKEEN P h e n o l c o n s u m p t i o n p r o v i d e s a n index t o t h e a c t i v i t y o f o t h e r c h e m i c a l p r o c e s s i n d u s t r i e s . F r o m 40 t o 100 m i l l i o n p o u n d s i s n o w u s e d for weed c o n t r o l a l o n e , which m e a n s h u g e s t r i d e s f r o m t h e 1938 figure, w h o s e g r a n d t o t a l w a s a b o u t 9 0 m i l l i o n p o u n d s JL HENOL is an excellent criterion for measuring the degree of activity in some industries. Obtained directly or indirectly from benzene, phenol reflects the level of steel operations, and its consumption indicates the magnitude of the industries producing plastics, plywood, dyes, petroleum, and pharmaceuticals. During war years, nearly 165 million pounds ^were consumed annually. Last year, total production was almost 270 million and producers were forced into voluntary allocation of the supply. As this situation continues, a review of the capacity to produce becomes of special interest. Upa and Downs Since the inception of the domestic industry in 1914, there has been either a phenol "feast or famine." From 1923 until 1941, capacity was for the zmost part more than equal to ail demands. Thereafter, an alternate insufficiency of benzene and facilities has presented obstacles that probably will nob be surmounted for several years more. The potential demand is estimated variously from 375 to 600 million pounds and compares with an annual consumption of 56 million pounds during the period 1936-39. Expansion of the industry in both wars was by way of the synthetic product. By any of several processes, 1 degree to 2 degrees benzene is converted to phenol. Operations are limited only by the availability of the raw material and installations for conversion. In contrast, the amount of phenol native to tars is limited both in content and by coke oven and gas works practice. Only the generally adequate supply of benzene has made possible the phenomenal grovsnth of the industry. Capacity to produce synthetic phenol was close to 90 million pounds in 1938, accounted for by the Dow and Monsanto companies. Two years later, the new Durez and Barrett plants began operation. However, military requirements, mostly for plastics and nylon, became significant. The government decision to supply Russia with nearly 11 million pounds during the seven months ending June 1942 led the Office of Production Management to place phenol under 2256
field plant of General Electric started contributing to the supply in 1946. While the Tuscaloosa unit of Reichhold Chemicals was in operation-December 1943, capacity was not approached until two years later. The Memphis plant, acquired by the Heyden Chemical Co. late in 194«, is not yet reported to have produced phenol. Finally, the Solvay plant was in production for only a few months in 1943-44. These installations, totaling 58 million pounds, as rated, were of little value during war years. During the period 1942-45, direct military and export quotas were nearly 50 million pounds per year. Consumption of phenol to make end products diverted to war uses accounted for almost all the rest. It is unlikely that the civilian supply exceeded 15 million pounds annually for all uses, about 25% of the 1936-39 production average. A great backlog demand was thus created at a time when new uses and applications were rapidly developing. With the end of hostilities, the military and export requirement suddenly abated and the industry reduced operations. There was phenol and to spare. Within a few months, the demand outstripped the means to supply and plans for expansion were made once more. Last
monthly allocation effective December 1941. The Russian commitment soon became 2 million pounds monthly and nearly as much r/as required to make ammonium picrate for the United States armed forces. Other quotas increased and the British received larger amounts under Lend-Lease. The only relief offered was when benzene replaced phenol in the production of nylon. Even so, the net demand far exceeded the supply, and the apparent difficulty was the lack of synthetic plants. Accordingly, WPB inaugurated a program that contemplated the building of 10 new units. This new capacity totaled 128 million pounds. Independently, Catalin assembled a small unit in 1942. Benzene Limited In .spite of the scarcity of equipment, installations were completed in 1943. It then became apparent that benzene was the limiting factor because of competing war demands, and the producers of phenol were poorly supplied. The Pitts-
Table I.
1913 1014 1915
Natural and Synthetic Phenol: New Supply and Exports
New Supply Net 9,346* 11,383^
(In thousands of pounds) Total* 1.000* 3,000*
Production Synthetic 0 2,000*
Natural 1.000* 1,000*
Imports 6 8.346 8,393 3,106
1918
100,599
106,794
100,000*
1922 1923 1924 1925 1926 1927 1928
1.559 3,208 11.021 15.089 8,935 8,654 11,205
1,286 3.311 10.522 14.734 8.691 8.041 10.227
0 1.300 • 8.000* 12.000* 7.000* 6.000« 8.200*
1.286 2.000* 2,5006 2.7006 1.7006 2.0006 2.0006
'496 130 550 355 244 613 978
1936 1957 1938 1939 1940 1941 1942 1943 1944 1945 1946 1947
47.537 65.722 44.548 60.519 91,851 111,861 127.016 164.129 178,686 188.260 179,143 247.477
48.724 65.690 44.548 68.577 96.155 115.047 146.125 194,967 201.993 205.112 203 829 268,460
36.700/ 50.900/ 30.750/ 53.000/ 72.188 92.922 127.632 181.347 173.141 181.640 183.855 245.000*
12.000* 14.800* 13.800* 15.600* 23.968 22.125 18.493 13.620 28,852 23,472 19.974 23.500*
71 32
Exports *
6,478
7,000
51
1,258 2.058 4.304 3.186 19.109 30.838 23i307 16.852 24.686 20,984
• Dye* A Synthetic Chemical*, U. S. Tariff Commission. 1918-46 1947, preliminary. & Foreign Comwigat\ all erades of' phenol—i.e.. 30%; data obtained from analyses in various tariff nerre « 0 10 • 4 20« 6 20• 6 20• 6 20• 5 14• 4 90 0 90 2 90 0 90 2 118 0 118 4 118 0 118 4 154.5 0 154.5 5 250.5 30 220.5 7 255 30 225 6 255 30 225 6 258 30 228 6 300 30 270 6 35S 28 330 G 40 431/ 427 7 6104? 5069 550 546 * 1938-, as developed from announcements and communications; rated signifies expected and as • engineered to obtain whether operative or not. b Rated capacity less t h a t shown to be obtainable subsequently; doe* not include capacity inoperative because of benzene shortage; the Memphis, Solvay, and GE plants makp up the totals. c Realizable capacity (sec &): includes the GE plant to the capacity obtained.
