Product profiles under the Organic chemicals are aimed at giving an overview to readers about nine major chemicals from the twenty chemicals tracked under the organic chemicals industry in India.

In this chapter, the chemicals are presented in the following order:
A. Methanol
B. Formaldehyde
C. Acetaldehyde
D. Acetic Acid
E. Acetic Anhydride
F. Ethyl Acetate
G. Aniline
H. Phenol
I. Acetone

A. Methanol

Methanol is a clear odourless liquid but it is a highly flammable chemical, which is toxic and extremely poisonous. Among the various organic chemicals produced in the industry, methanol is an important feedstock for the chemical industry. Methanol can be produced from any carbon source such as natural gas, coal, and biomass. Natural gas is the most popular feedstock to produce methanol.

Uses

Methanol is an important feedstock for many sectors of the chemical industry. For example, acetic acid another important chemical used widely in the chemical industry, is produced from methanol. Methanol is a key building block for various chemicals that are used in the production of polyester, polymer and fuels.

Preparation of Methanol

Methane component in natural gas is used for the production of methanol. Methane reacts with steam on a nickel catalyst to produce syngas at a moderate pressure of 1 to 2 MPa (10–20 atm) and high temperature (around 850°C). Technology for methanol production is available for licensing from few multinational companies such as Imperial Chemical Industries (ICI), and Haldor Topsoe Ltd and Indian manufacturers of methanol use licensed technology from these multinationals.

Major Producers of Methanol

There are five main producers of methanol in India. Gujarat Narmada Valley Fertilizers Company Ltd (GNVFC) is one of the leading producers of methanol in India. GNVFC, Deepak Fertilisers, and Assam Petrochemicals use technology from ICI to produce methanol, while Rashtriya Chemicals & Fertilizers Ltd (RCF) and National Fertilizers Ltd use technology from Haldor Topsoe Ltd.

B. Formaldehyde

Formaldehyde is one of the basic organic chemicals and is used as a basic building block in various downstream industries. Formaldehyde is a colourless gas with a strong pungent odour. It is also known as methanal and formalin. The term formaldehyde is used to describe formaldehyde in various mixtures (with water and alcohol). Formalin refers to an aqueous solution that contains 37 to 50% of formaldehyde and 6 to 15% of alcohol stabiliser. Due to its relatively low
cost, high purity, and variety of chemical reactions, formaldehyde has become one of the most important industrial and research chemical.

Uses

Formaldehyde is used to produce urea formaldehyde (UF) resins, phenolic (PR) resins, polyacetal resins, butanediol, methylene di-isocyanate (MDI), pentaerythritol, urea formaldehyde concentrates, hexamethylene tetramine, melamine resins, and other miscellaneous chemicals.

Formaldehyde has disinfectant properties due to which it is used in soap as a disinfectant. Formaldehyde in hydroalcoholic solution is used widely in the sterilisation of surgical goods. It is also used as a preservative in cosmetic products to increase their effectiveness against different micro-organisms. Smaller amounts of formaldehyde are also used to make lubricants, in leather tanning, paper coating and laminating, photographic chemicals, dyes, well-drilling muds, and to impart wrinkle resistance to fabrics. Formaldehyde is mainly used in plywood, paint, and pharmaceutical industries.

Growth in formaldehyde consumption is generally correlated with growth in the construction industry.

Preparation of Formaldehyde

The most general process for manufacturing formaldehyde is partial oxidation and dehydrogenation of methanol using a silver catalyst, or partial oxidation of methanol using a metal oxide catalyst. There are numerous process licensors in the international market who license either kinds of process. The efficiency of each process depends on the sophistication of the technology. Most of the technology suppliers for formaldehyde are non-Indian firms.

Major Players of Formaldehyde

Kanoria Chemicals & Industries Ltd and Allied Resins & Chemicals Ltd are the major manufacturers (among the listed players) of formaldehyde.

C. Acetaldehyde

Acetaldehyde is a chemical intermediate, and is a colourless liquid. It is flammable and has a fruit like odour. Being a chemical intermediate, acetaldehyde is used for producing acetic acid, pyridine and pyridine bases, peracetic acid, pentaerythritol, butylene glycol, and chloral. Acetaldehyde is also used for producing ethyl acetate, isobutyl acetate, crotonaldehyde, flavor and fragrance acetals, acetaldehyde cyanohydrin, acetaldehyde oxime, paraldehyde, metaldehyde, polymers, and various halogenated derivatives.

Uses

Acetaldehyde has been used in manufacturing aniline dyes and synthetic rubber, silver mirrors, and to harden gelatin fibres. It has also been used in producing polyvinyl acetal resins, in fuel compositions, and to inhibit mould growth on leather. Acetaldehyde is also an input in the manufacture of disinfectants, drugs, perfumes, explosives, lacquers and varnishes, photographic chemicals, phenolic and urea resins, rubber accelerators and antioxidants, and room air deodorisers. Acetaldehyde is also a pesticide intermediate. Acetaldehyde, an alcohol denaturant, can also be used as aflavouring agent and adjuvant. It is an important component of food flavourings and is added to milk products, baked goods, fruit juices, candy, desserts, and soft drinks. Finally, acetaldehyde is also used in manufacturing vinegar, yeast, and as a fruit and fish preservative.

Preparation of Acetaldehyde

Depending on the input, acetaldehyde can be oxidised from ethylene or dehydrogenated from ethanol. It is produced by oxidation of ethylene in water in the presence of palladium catalyst. Acetaldehyde is also produced from dehydrogenation of ethanol in presence of metal catalysts such as copper or nickel. In India, major acetaldehyde producers produce it through ethanol/ industrial alcohol process.

Manufacturers of Acetaldehyde

Acetaldehyde is an intermediate chemical and is produced in-house for production of value- added chemicals. Kanoria Chemicals & Industries Ltd (KCL) and Trichy Distelleries & Chemicals Ltd (TDCL) are among the known manufacturers of acetaldehyde.

D. Acetic Acid

Acetic acid or ethanoic acid, one of the world’s most important chemical, is used in a variety of products, including textiles, food processing and pharmaceuticals. It is commonly known as vinegar. Acetic acid is colourless both in the liquid and solid forms and has a sour taste and pungent smell.

Uses

Acetic acid is an important chemical used to produce downstream products; these products are used in a variety of industries such as pharmaceutical, food, polymer and polyester industries. The chemical finds major application in manufacturing vinyl acetate that is used in paints and adhesives and coatings. Acetic acid is also used to manufacture PTA and acetic esters such as methyl acetate, ethyl acetate, butyl acetate, acetic anhydride, cellulose acetate and chloro acetic acid.

Preparation of Acetic Acid

Acetic acid can be produced through a variety of processes from multiple feedstocks. Oxidation of acetaldehyde to acetic acid is the most popular process. Acetic acid can also be produced by reacting carbon monoxide with methanol.

Major Manufacturers of Acetic Acid

Gujarat Narmada Valley Fertilizers Company Ltd, Jubilant Organosys Ltd, IOL Chemicals & Pharmaceuticals Ltd, Trichy Distilleries & Chemicals Ltd, Pentokey Organy (India) Ltd and Kanoria Chemicals & Industries Ltd are among the main producers. Majority of the producers of acetic acid are located in Western India.

E. Acetic Anhydride

Acetic anhydride is a colourless liquid with a pungent odour that is used to produce various chemicals, pharmaceuticals, dyes, and perfumes.

Uses

It is also used to manufacture specialty esters, herbicides, pesticides, dyes, and food ingredients. VAM and cellulose acetate are among the biggest consumers of acetic anhydride. Acetic anhydride is used in synthesis of popular drugs such as aspirin and paracetamol. It is also used in manufacturing tetra-acetyl ethylene diamine, which is used in washing powder formulations. Moreover, in India, acetic anhydride has been declared as a ‘controlled substance’ under the Narcotic Drugs and Psychotropic Substances Order and sellers and buyers have to register themselves with the Narcotics Control Board. Producers and users of acetic anhydride are required to report fortnightly to the Narcotics Control Board about their usage or selling pattern and the stocks they hold.

Preparation of Acetic Anhydride

Acetic anhydride can be manufactured from acetic acid (ketene process), methyl acetate (carbonylation process), and acetaldehyde (oxidation process). The ketene-based process and the methyl acetate carbonylation route are currently the major economic processes used in the global industry. Liquid phase oxidation of acetaldehyde has almost been replaced by these two processes.

Major Manufacturers of Acetic Anhydride

Andhra Sugars Ltd, IOL Chemicals & Pharmaceuticals Ltd (IOL), and Jubilant Organosys Ltd are the well-known producers of acetic anhydride in India.

F. Ethyl Acetate

Ethyl acetate is a colourless liquid with a fruity odour; it is soluble in most organic solvents, such as alcohol, acetone, ether and chloroform. It finds wide application as a solvent across many industries; however, ethyl acetate is only slightly soluble in water.

Uses

Ethyl acetate is used in industries that cater to end consumers, for example, paints, perfumes, and food industry. Ethyl acetate is an active solvent, and is mainly used in industrial lacquers and enamels. Thus, the paint and printing industry is one of the major consumers of ethyl acetate. It is also used in the manufacture of perfumes, artificial fruit essences, aroma enhancers, and artificial flavours for confectionary, creams, and cakes. In addition, ethyl acetate finds use in flexible packaging due to its evaporation properties, and its use in the extraction of camphor, oil, fats, and antibiotics.

Preparation of Ethyl Acetate

Esterification using acetic acid and ethanol is one of the processes available for the production of ethyl acetate. This seems to be the main process for roduction of ethyl acetate in India.

Major Manufacturers of Ethyl Acetate

There are numerous players in the organic chemical industry who manufacture ethyl acetate. IOL Chemicals & Pharmaceuticals Ltd is the largest producer of ethyl acetate. Some other major manufacturers who produce Ethyl Acetate are Laxmi Organic Industries Ltd, Ghaziabad Organics Ltd, Trichy Distilleries & Chemicals Ltd, Kanoria Chemicals & Industries Ltd.

G. Aniline

Aniline is a colourless liquid with an unpleasant odour. It burns with a smoky flame, is toxic, and is a potential carcinogen. Aniline is an aromatic amine and is used as an intermediate. It is majorly used in manufacturing dyestuffs. Aniline is majorly used for conversion to methylene diphenyl diisocyanate (MDI). Aniline is the base component for several rubber compounding agents. It is also used as an intermediate for dyes, drugs, and other intermediate chemicals. Hydroquinone is another chemical that is manufactured from aniline. Hydroquinone is used in photography and to produce poly ether ether ketone, a omponent in high performance plastics.

Preparation of Aniline

Nitrobenzene process and ammonolysis of phenol are the two main processes used for manufacturing aniline. The nitrobenzene process is the traditional process to manufacture aniline, while ammonolysis of phenol is a recentlydeveloped commercial process for manufacturing aniline, in which phenol is reacted with ammonia in the presence of a catalyst to derive aniline.

Major Producers of Aniline

Hindustan Organic Chemicals Ltd (HOCL) and Gujarat Narmada Valley Fertilizers Company Ltd are the largest producers of aniline.

H. Phenol

Phenol is a colourless, toxic, corrosive chemical with a peculiar odour.

Uses

It is used to manufacture phenolic resins, caprolactum, alkylphenols, aniline, bis-phenol A, adipic acid, plasticizers, and pharmaceutical products. It is also used in water treatment and medicinal preparations. Phenol is an important aromatichydrocarbon that is used to produce a variety of compounds. These compounds have applications in multiple industries such as plastics and fibres.

Preparation of Phenol

Cumene oxidation process is the primary process for production of phenol. Cumene or isopropyl benzene is oxidised to get cumene hydroperoxide, which is then split to derive phenol and acetone. Acetone, another important solvent, is derived as a by-product in this process.

Major Manufacturers of Phenol

Hindustan Organic Chemicals Ltd and Scehenectady International Group India Ltd (SI) are the two major domestic producers of phenol.

I. Acetone

Acetone is a colourless liquid that is flammable and hence highly explosive in nature. Acetone has an irritating property but is not toxic.

Uses

Acetone serves as an important solvent and is used to manufacture methyl methacrylate (MMA), isophorone, and bisphenol-A (BPA). It is used to produce methyl isobutyl ketone (MIBK) for specialty coating applications. In addition to being an important solvent, acetone is used to produce a variety of downstream chemicals. These chemicals are used in a variety of industries, which include drugs and paints industry.

Preparation of Acetone

Acetone is mostly manufactured from cumene. The cumene oxidation process is the most popular process for manufacturing acetone. Dehydrogenation of isopropanol in the presence of zinc oxide catalyst is the next popular process to produce acetone. Acetone is also produced from ethyl alcohol; in this process, ethyl alcohol vapours are mixed with steam, pre-heated and passed over zinc oxide or zinc chromite catalyst to derive acetone.

Major Manufacturers of Acetone

There are two listed manufacturers of acetone in India - Hindustan Organic Chemicals Ltd and Schenectady International Group - India Ltd.