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Which petroleum and natural-gas by-products are used to make synthetic fibres?

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Figure 1: Three common polymer structures. The linear, branched, and network architectures are represented (from top), respectively, by high-density polyethylene (HDPE), low-density polyethylene (LDPE), and phenol formaldehyde (PF). The chemical structure and molecular structure of highlighted regions are also shown.
man-made fibre Figure 1: Three common polymer structures. The linear, branched, and network architectures are represented (from top), respectively, by high-density polyethylene (HDPE), low-density polyethylene (LDPE), and phenol formaldehyde (PF). The chemical structure and molecular structure of highlighted regions are also shown.

Synthetic fibres are produced from polymers derived primarily from by-products of petroleum and natural gas. These raw materials, known as petrochemical feedstocks, are processed into specific chemical building blocks used to manufacture various fibres.12

Key by-products and their applications include:

  • Olefins: This group includes ethylene, propylene, and butadiene. Ethylene is used to create ethylene glycol, a vital component in polyester fibres, as well as vinyl chloride for polyvinyl chloride (PVC) fibres. Propylene is used to produce polypropylene fibres, often utilized in carpets, and the derivative acrylonitrile, which is the primary material for acrylic fibres. Butadiene is used in the production of carpet fibres.2345
  • Aromatics: Major feedstocks include benzene, toluene, and xylene. Benzene is a critical raw material for nylon, while xylenes are used to manufacture terephthalic acid, which is combined with ethylene glycol to create polyester fibres.24
  • Synthesis Gas: Used to produce methanol, which is subsequently employed in the manufacture of polyester fibres.2