Chimica industriale - produzione dell'industria chimica

What is the chemical sector (& nomenclature)

• Facts and figures
• Characteristics of the chemical industry
• Top chemicals
• Structure of chemical industry
• Energy products: natural gas and refinery
• Petrochemistry

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The chemical industry transforms raw materials (organic, inorganic) and converts them to substances or products for consumers or other industrial sectors.

The products of the chemical industry have various applications and uses:

• Base chemicals, mainly for further transformation inside the chemical industry
• Intermediate products, for further transformation inside or outside chemical industry
• Final products for industrial system, agriculture, services, consumers, etc.

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• Not a single product, but many (over 30.000)
• Very broad range of applications (from energy, to health care, to materials - polymers, ....)
• The input for a large manufacture sector
• Strictly correlated (many interdependent passages from raw materials to final products)
• Energy and raw material dependence
• Global scale
• Scale-economy

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Structure of chemical industry

Raw materials Base chemicals Intermediate

Inorganic Inorganic Intermediates

(H₂O, air, minerals, metals, Si, glass, ceramics, NaCl, SiO₂, ….)

(NH₃, H₂, H₂SO₄, HCl, H₃PO₄, Cl₂, zeolites, inorg. fibres, …)

(formaldehyde, acetic ac., ethylene oxide, vinylchlorure, vinyl acetate, acrylonitrile, meta-acrylic acid, phthalic & maleic anh., phenol, …)

Fossil fuels Base chemicals

(coal, oil, natural gas)

(syngas- CO/H₂, alkanes, olefins, aromatics, HCN)

Energy Base chemicals Final products

(from other sources)

(CH₃OH, ethanol, methylamine, halogen compounds, acetaldehyde, ethanolamines, acetone, ..)

Polymers & elastomers, fibres, detergents, agro-chemicals, pharmaceuticals, ...

Biomass

Inorganic industrial chemistry

Refinery

Petrochemistry

Polymer sector

Fine and specialty chemicals

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Each industry a three-digit code nr.: chemical manufacturing 325.

Sectors, subsectors and sub-subsectors four, five, and six digit nr.

Basic Chem. Manuf. 3251, Dyes and Pigments 32513, Synth. Org. Dyes and Pigments 325132.

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The manufacturing sector contributed about $2.0 trillion of value added, which was about one-fifth of that year’s gross domestic product (GDP

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Production and transformation processes

Production and transformation of organic and inorganic substances which utilize the following procedures: alkylation, carbonylation, oxidation, hydrolysis, polymerization, ....

Treatment of org. & inorg. substances which use the following processes: distillation, extraction, .....

Transformation of oil and related products (refinery)

Production and treatment of gases for energy uses

Production of metals by wet processes or through the use of electrical energy (Al)

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Cefic 2007 report

In 2006, world chemicals sales were estimated at €1641 billion, an increase of 9% compared to the previous year. With €476 billion, the EU chemical industry is still in a top position, but has lost its first place in the ranking to Asia (including China and Japan), mainly due to the rise of China and India. In 2006, China occupied the third place in worldwide chemical sales and India ranked seventh, so both are among the world’s ten largest chemical producers. Taken together, the EU, Asia and NAFTA (North American Free Trade Area) account for almost 90% of the world turnover. www.cefic.org

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Output of the chemical and pharmaceutical industries

The output of the chemical and pharmaceutical industries covers four wide ranges of products: base chemicals, speciality and fine chemicals, pharmaceuticals and consumer chemicals.

• Base chemicals cover petrochemicals and derivatives and basic inorganics. They are produced in large volumes, and are sold to the chemical industry itself or to other industries. They represented nearly 43% of total EU chemicals sales in 2006.
• Specialty chemicals cover the auxiliaries for industry, dyes & pigments, crop protection, and paints & inks. Specialty chemicals are produced in small volumes but nevertheless represented 19% of total EU chemicals sales in 2006.
• Pharmaceuticals represent both basic pharmaceutical products and pharmaceutical preparations. They accounted for 28% of total EU chemicals sales in 2006.
• Finally, consumer chemicals are sold to final consumers: soaps and detergents, perfumes and cosmetics. They represented approximately 10% of total EU chemicals sales in 2006.

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Chemical consumption by downstream users

The chemical industry underpins virtually all sectors of the economy and its strategies impact directly on the downstream users of chemicals.

The consumption structure of chemicals by downstream users gives the following picture:

• The big industrial customers of chemicals are the metals, mechanical & electrical industries, textiles & clothing, the automotive industry and paper & printing products, accounting together for 25.1% of chemical consumption by downstream users.
• 30.3% of chemicals consumption is absorbed by end users in private households, government and non-profit organisations, 16.4% goes to services, 6.4% to agriculture, 5.4% to construction, 6.1% to the rest of manufacturing and 10.3% to other industries.

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Added value and operating profit

Chemicals is the second leading manufacturing sector (after pharmaceuticals) in terms of "added value per employee" in Europe, followed by the “office machinery and computers”, “radio, television and communication”, basic metals”, “automotives” and “pulp and paper” sectors. The chemical industry’s added value per employee is almost twice as high as the manufacturing average.

With regard to its gross operating profit, the chemicals sector compares very favourably to other manufacturing sectors as well. The ratio of gross operating profits to sales is the 5th highest in industry and is well above the manufacturing average.

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Contribution to EU gross domestic product

The chemical industry's contribution to the EU gross domestic product amounts to 1.3%. When pharmaceuticals are added this figure amounts to 2%. This may seem small at first sight, but should be re-assessed taking into consideration both the shrinking contribution of industry as a whole to GDP in advanced economies (-7% over the last 5 years in the EU) along with a rise in services. Additionally, there is a wide contribution of chemical products into all branches of the economy; for example in Germany chemicals are the most important supplier of innovative materials for the industry. In Germany chemicals represent 10% of the supply of input and intermediary products and they show an above average R&D content. Chemicals account for more than 7% of manufacturing value added and more than 6% of industry value added in Europe.

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World chemicals majors

In 2006, almost half (14) of the 30 world chemicals majors had their headquarters in the EU - representing 16% of world chemicals sales. These 30 companies had a combined sales turnover of €526 billion. This was a significant increase compared to the previous year and reflects not only the positive sales development in 2006 but also the ongoing consolidation in the chemicals sector. Additionally, Asia (excluding Japan) develops more and more as a leading region in chemicals. Three out of the five companies headquartered in “other countries” come from Asia, namely China and South Korea.

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The EU chemical industry comprises about 27 000 enterprises (data covering firms with no employees are excluded), 96% of which have less than 250 employees and may be considered as small and medium sized enterprises. These account for 30% of sales and 37% of employment. Only 4% of the EU enterprises employ more than 249 employees and generate 70% of total chemicals sales.

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EU chemicals trade surplus

In 2006, the trade surplus amounted to €40.6 billion. Specialty chemicals accounted for more than 37% of the EU chemicals trade surplus, with a trade surplus of €15.3, billion. With €13.4 billion consumer chemicals are the second strongest sector on the world markets, followed by petrochemicals (€7.7 billion) and polymers (€6.9 billion). Basic inorganics is the only sector with a trade deficit of €2.7 billion. Pharmaceuticals account for a trade surplus of €34.8 billion which would have to be added to the €40.6 billion.

To put the EU chemicals trade (including pharmaceuticals) into an international context, in comparison with the USA and Asia, the EU is the only region with a trade surplus in chemicals and it is also the extent of the trade surplus that marks the difference. The USA has had a negative trade balance in chemicals since 2002 and the Asian trade deficit in chemicals has been continuously rising over the last 10 years.

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Innovation and growth

In addition to providing for customers' present needs, the chemical industry is constantly developing new and improved products and processes, creating and serving completely new markets. This enables other industries to be more efficient and productive by using more effective substitute materials and products. Chemicals serve as input into basically all sectors of the economy and consequently depend on their economic performance.

In the period 1996-2006, the chemical industry had an average growth rate of 1.7% whereas total industry and GDP grew by 2.1% and 2.4% respectively on average per year. These averages mask however quite different yearly growth rates in chemicals, from -2.7% in 2001 to 6.3% in 1997. The range for yearly industrial growth is much smaller, from -0.2% in 2002 to 4.6% in 2000.

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Purchases, energy costs and gross value added

In 2004, purchases by the EU chemical industry accounted for 74% of the sales value. The remaining 26% constitutes the gross value added of the sector, which comprises gross operating surplus and payroll. Among purchases, it is possible to single out the costs of trading and energy. Trading represents the cost of chemicals purchased from third parties and resold in their original condition, and amounts to 4% of the sales value. Energy costs from the purchase of feedstock and fuel and power currently account for 8% of the sales value. However, it needs to be underlined that this is an average. Certain sub sectors are much more sensitive to energy cost as for them it represents a more important input factor, for example the Chlor Alkali industry. In 2004, the payroll accounted for some 14% of the chemicals sales value. The gross operating surplus is defined as profits before taxes,