Petrochemistry

Petrochemistry

Note

Design stage. This page describes planned mechanics from the design document. Not implemented yet — see Roadmap (milestone M9; chemical accidents arrive with M10).

Petrochemistry and basic chemistry is industrial era I3. It turns refinery and gas-plant streams into ethylene and propylene, salt into chlorine and caustic soda, natural gas into hydrogen and methanol, and all of these into polymers, resins and special chemicals. Many of its products are gates for other industries: polyethylene becomes cross-linked xlpe cable for 110 kV lines, PTFE seals handle UF₆ and HF, ion-exchange resins capture uranium, and tributyl phosphate is the PUREX extractant.

Pressure, temperature, composition and heat balance are honest. You learn a unit's state from instruments and build its controls on a PLC — no ready-made regulators.

Player path through era I3

I1–I2: coke gasifier ─► water gas ─► CO shift ─► H₂ (ammonia)
ethane from the gas plant ─► steam cracker ─► cold separation ─► ethylene, propylene
   ├─► LDPE ─► cables ─► Co-60 irradiation ─► xlpe     ├─► polypropylene (99.5 % propylene)
   └─► butadiene + styrene ─► SBR rubber ─► belts and seals
brine (rock_salt) ─► diaphragm electrolysis ─► Cl₂, NaOH, H₂
   ├─► PVC ─► 0.4 kV cables     ├─► HCl ─► trichlorosilane (silicon)
   └─► chloroform + HF ─► R-22 ─► TFE ─► PTFE ─► membrane ─► membrane electrolysis
sales gas ─► steam methane reforming ─► H₂ ─► methanol ─► formaldehyde ─► bakelite (with coke-plant phenol)
benzene + ethylene ─► styrene ─► ion-exchange resins;  phenol + epichlorohydrin ─► epoxy
potatoes, sugar cane ─► ABE fermentation ─► butanol + POCl₃ ─► TBP (PUREX)

Reference chemical complex: an ethane cracker (0.5 kg/s) with 8 separation columns, SMR (0.05 kg/s H₂), methanol 0.3 kg/s, a 32-element chlor-alkali line (13 t Cl₂/day), 4 batch reactors, a loop reactor, an LDPE autoclave and 2 ethylbenzene/styrene reactors.

How it is simulated

Level	Model	Time domain
Media: cracked gas, olefins, chlorinated organics, methanol, aromatics	PetchemPackage: 21 components, Peng–Robinson	FAST
Gases and solutions: syngas, H₂, Cl₂, HCl, NH₃; brine, caustic, acids	gas mixture package; water package with one dissolved solute (solution_strength, 1 % steps)	FAST
Furnaces: cracking, methane reforming, EDC cracking, R-22 pyrolysis	TubeFurnace: fired side via Combustor, coil in 8 cells	real time
Continuous reactors	process units with continuous kinetics	real time
Batch vessels: PVC, PTFE, SBR, resins, TBP	process units in SLOW ×72; heat balance FAST	SLOW + FAST
Electrolysis	Faraday + cell voltage curve, membrane degradation	FAST / SLOW
Quality	polymer_grade, resin_spec, chem_lot; quality_lab	SLOW
Accidents	shared consequence pipeline → DamageBudget	FAST

Time rule. Continuous units (furnaces, gas separation, SMR, CO shift, PSA, methanol, chlor-alkali, HCl synthesis, loop reactors, LDPE autoclave) run in real time; only degradation is ×72. Batch units (batch_reactor, fermentation_vat, hot_press) run in SLOW ×72. The heat balance of every vessel is computed in FAST: in a batch vessel the reaction heat is multiplied by 72 and the jacket must remove 72× the power. The cooling margin is the same as in reality, and a runaway develops over real seconds and minutes — you can react to a cooling failure only if you designed the safety instrumented system.

Power comes from Create shafts (agitators, compressors, extruders), the grid (electrolysis through rectifier_unit), the combustion model (furnaces) and process steam.

Steam cracking

The tube furnace is a multiblock of tube_furnace_radiant (3×3×3, tubes=coil), tube_furnace_convection (3×3×3) and tube_furnace_controller, fired on methane-hydrogen off-gas or sales_gas. The coil is a consumable furnace_coil item with a steel_grade (HP-40Nb for hydrocarbons, nickel alloy for R-22). The same segments with tubes=catalyst make a steam methane reformer. Furnace efficiency with the convection section is 0.90–0.93.

Example: 0.5 kg/s ethane + 0.15 kg/s steam at 65 % conversion absorbs ≈ 1.9 MW and fires ≈ 4.5 MW; cracked-gas methane and hydrogen cover ≈ 60 % of the fuel.

Yield, wt %	Ethane, X = 0.65	Naphtha P/E 0.65	Naphtha P/E 0.55	Naphtha P/E 0.45
H₂ / CH₄	3.9 / 3.8	0.8 / 12.5	1.0 / 15.0	1.2 / 17.0
C₂H₂ / C₂H₄ / C₂H₆	0.4 / 52.0 / 35.0	0.3 / 25.5 / 4.0	0.5 / 29.0 / 3.5	0.8 / 32.0 / 3.0
C₃H₆ / C₃H₈	1.2 / 0.2	16.5 / 0.6	16.0 / 0.5	14.4 / 0.4
C₄H₆ / other C4	1.5 / 0.4	4.5 / 7.0	4.7 / 4.5	4.8 / 2.6
Pyrolysis gasoline / fuel oil	1.4 / 0.2	24.8 / 3.5	20.0 / 5.3	17.0 / 6.8

Ethane is recycled (ethylene yield with recycle ≈ 80 %). Naphtha yields depend on severity (propylene/ethylene ratio), which falls with higher coil outlet temperature and longer residence time.

Parameter	Ethane / naphtha	If off
Coil outlet temperature	820–860 / 800–850 °C	higher → more conversion and coke, lower P/E
Residence time	0.15–0.40 / 0.25–0.50 s	longer → secondary reactions, CH₄ and tar
Steam/feed	0.3 / 0.5 kg/kg	lower → coke ×1.5–2
Tube metal temperature	≤ 1100 °C (HP-40Nb)	creep

Coking and decoking. Coke builds up on the coil (run length ≈ 60 physical days ≈ 20 real hours); you see rising tube metal temperature and coil pressure drop, and the maintenance panel shows FURNACE_COKING. Decoking is your own sequential function chart: feed cut → steam → steam-air at 800–850 °C until CO₂ < 0.2 % (24–36 physical hours = 20–30 real minutes). Too much air causes local overheating and coil life loss.

Quench exchanger (quench_exchanger) cools cracked gas from 840 to 350–400 °C in ≤ 30 ms and raises 11–12 MPa steam. Slow quench costs 2 % ethylene per extra 10 ms. Without boiler water it burns out in minutes (CRK_TLE_LOW_BFW_LEVEL).

Gas separation.

cracked gas ─► quench_tower ─► 5-stage compressor to 3.6 MPa ─► caustic wash (CO₂, H₂S < 1 ppm) ─► zeolite drying
   ─► cold_box (−100…−140 °C) ─► demethanizer: H₂ + CH₄ → fuel, H₂ → PSA
   ─► deethanizer ─► C₂H₂ hydrogenation ─► C2 splitter ─► ethylene 99.9 %
   ─► depropanizer ─► C3 splitter ─► propylene 99.5 % ─► debutanizer ─► C4 / pyrolysis_gasoline

The C2 splitter needs ≈ 80 real trays, the C3 splitter ≈ 180 (two columns in series). That is why crude FCC propylene (≈ 70 %) without a C3 splitter goes only to fuel and cumene, never to polypropylene. Acetylene above 5 ppm in ethylene poisons Ziegler catalyst, and only a chromatograph (pc_analyzer) can see it.

Furnace states: COLD → DRYOUT → HOT_STANDBY → CRACKING / REFORMING; DECOKING; any trip → TRIPPED.

Syngas, hydrogen, methanol and nitrogen products

Coal gasification (early path, I1–I2). coal_gasifier (2 segments 3×3×3) runs a cycle on a coke bed: air blow 60 s (bed to 1200 °C, producer gas to a boiler) → steam purge 10 s → steam run 150 s → syngas (H₂ 50 %, CO 40 %, CO₂ 5 %, N₂ 5 %). Below 950 °C unreacted steam and CO₂ rise. Valves are switched by an A1 stepping programmer or an A3 sequential function chart — the first sequence automation task in chemistry. ≈ 0.6 kg coke per Nm³.

Steam methane reforming. Reformer tubes with catalyst_steam_reforming (Ni). At 850 °C, 2.5 MPa, steam/carbon 3: methane conversion 0.798, dry gas H₂ 73 %. Hazards: S/C below 1.8 deposits carbon; sulfur above 0.1 ppm (the odorant in sales_gas!) poisons nickel within 2–4 physical days unless you desulfurize with hydrotreating catalyst and a zinc_oxide_sorbent bed; tube metal above 950 °C creeps.

CO shift and hydrogen.

SMR / gasifier ─► waste heat boiler ─► HT shift Fe-Cr 350–450 °C (CO → 3 %) ─► LT shift Cu-Zn 200–250 °C (CO → 0.3 %)
   ─► CO₂ removal (amine) ─┬─► PSA (adsorber_vessel ×4): hydrogen 99.99 %, 85 % recovery
                           └─► methanator: CO + CO₂ < 10 ppm → ammonia synthesis

Per 1 kg H₂	Feed	Energy	CO₂
Water electrolysis	9 kg water	50 kWh electric	depends on power source
SMR	2.49 kg CH₄ + ≈ 0.9 kg fuel	≈ 170 MJ + ≈ 1 kWh	≈ 9.3 kg to the emissions ledger

SMR is about 3× cheaper in primary energy; electrolysis stays as the gas-free path and an oxygen source, and matters under CO₂ quotas.

Methanol. fixed_bed_reactor with catalyst_methanol (Cu/ZnO/Al₂O₃), 5–10 MPa, 220–280 °C, boiling water on the shell side (4 MPa steam). Equilibrium CO conversion at H₂/CO = 2: 0.642 at 250 °C and 8 MPa. A pass reaches 0.3–0.5 of equilibrium, so the loop recycles 4–5× with an inerts purge. Optimum stoichiometric number 2.05: SMR gas gives 2.8–3.0 (excess H₂ to purge), gasifier gas ≈ 1.1 (needs partial shift). Two columns → methanol 99.85 %.

Formaldehyde. Silver process (600–650 °C, 86–90 %, mixture above the upper flammable limit) or Formox (Fe-Mo, 250–400 °C, 92–95 %, below the lower limit). Crossing the flammable range at startup flashes back — interlock FORM_FEED_RATIO. Absorbed to formaldehyde_solution 37 %.

Nitrogen products. Ammonia comes from the ammonia synthesis reactor (H₂ from here + N₂ from air separation).

Product	Conditions	Use
ammonium_nitrate	NH₃ + HNO₃, 0.4 MPa, 180 °C, evaporated to 95 %	mine blasting (ANFO: 94 % + 6 % diesel_fuel), fertilizer
Hexamine	6 HCHO + 4 NH₃, 30–50 °C	bakelite hardener
Methylamines	CH₃OH + NH₃, 350–450 °C	resin amination
urea	14 MPa, 185 °C	backlog

Ammonium nitrate is an OXIDIZER: it decomposes above 210 °C, faster with chlorides, acids, organics and metals; a large mass in confinement detonates. Batches carry a chem_lot component — contaminated nitrate decomposes at lower temperature.

Chlor-alkali

Brine. rock_salt from salt domes is dissolved in a leach_tank to 305–310 g/L → brine. Primary purification (soda ash + NaOH, precipitation, thickener) brings Ca and Mg to 1–5 mg/L. Membrane cells also need secondary purification on a chelating ion_exchange_resin (Ca + Mg < 20 µg/L) and dechlorination of depleted brine.

Electrolyzer. 2 NaCl + 2 H₂O → Cl₂ + H₂ + 2 NaOH. A filter-press of chlor_alkali_cell elements (1×3×1, 2.7 m² active area), up to 32 in series between two chlor_alkali_end_plates connected to busbar_dc, fed by rectifier_unit (6–10 kV class). Bipolar: voltages add, current is common.

Cell insert	Era	U₀, V	Current density, kA/m²	Current efficiency	Caustic	DC energy, kWh/t Cl₂
Diaphragm (diaphragm_pack)	early I3	2.30	2.0–2.7	0.94	10–12 % NaOH + 15 % NaCl	2775 at 3.45 V
Membrane (ion_exchange_membrane)	I3 after PTFE	2.35	4–6	0.96	32 % NaOH, NaCl < 50 ppm	2284 at 2.9 V

Example: one element at 5 kA/m² (13.5 kA) makes 17.14 kg/h Cl₂, 19.34 kg/h NaOH and 0.487 kg/h H₂ at 39.2 kW. A line of 32 elements: 92.8 V, 1.25 MW, 13.2 t Cl₂/day.

• The diaphragm is steel mesh plus mineral_fiber (real diaphragms used asbestos; the mod deliberately does not add asbestos). Diaphragm caustic must be evaporated with salt removal, needing 3× more steam than membrane caustic — that is the incentive to switch.
• The membrane is a perfluorinated film based on ptfe. It degrades with brine hardness above 20 µg/L and with reverse currents on shutdown; good brine gives 3–5 physical years, 200 µg/L only months. Maintenance fault MEMBRANE_DEGRADATION.
• The hydrogen side must be held 20–40 mbar above the chlorine side; you design the differential pressure controller. Out of range → CA_DIFF_PRESSURE_HIGH/LOW. A punctured membrane lets H₂ into chlorine (explosive at 4–89 % H₂).

Stream	Treatment	Notes
Wet Cl₂ 85 °C	titanium coolers, drying with 96 % H₂SO₄, compression 0.4–1.2 MPa, liquefaction	moisture > 50 ppm accelerates steel corrosion ×100
Liquid chlorine	gas_storage_bullet, chlorine_cylinder (1 t)	vapour pressure 0.78 MPa at 25 °C
Catholyte 32 %	3-effect evaporator to 50 %	sodium_hydroxide_solution
H₂	cooling, mist removal	99.9 %, to HCl synthesis and fuel

Steel burns in chlorine above ≈ 250 °C; steam tracing a dry chlorine line above 120 °C is refused by the validator (CA_CL2_LINE_HIGH_TEMP).

HCl. hcl_synthesis_furnace burns H₂ in Cl₂ (5–10 % H₂ excess) → hydrochloric_acid 31–36 % or dry hydrogen_chloride for trichlorosilane (silicon production) and oxychlorination. Balancing HCl across the complex is your puzzle.

Polymers

All polymer reactors share one heat-balance and runaway model (RunawayModel). Runaway starts when the slope of heat generation exceeds the slope of heat removal (Semenov criterion); the critical temperature rise above coolant is about RT²/Eₐ (11.3 K at 330 K, 80 kJ/mol). Adiabatic rise shows how a cooling failure ends: a vinyl chloride suspension heats by ≈ 198 K, and vinyl chloride vapour pressure exceeds the vessel design.

Monomer	Heat of polymerization, kJ/mol
Ethylene	93
Propylene	84
Butadiene / styrene	73 / 73
Vinyl chloride	72 (up to 96 industrial; default 1.5 MJ/kg)
Tetrafluoroethylene	163

Melt flow index (grade) is set by hydrogen chain transfer for HDPE and PP, and by temperature and modifier for LDPE.

Polymer	Blocks	Conditions	Product
LDPE	hyper_compressor (reciprocating, Create shaft) → high_pressure_autoclave	150–200 MPa, 180–280 °C, peroxide or 20–50 ppm O₂ initiator, 15–20 % per pass	polyethylene LDPE, 918–930 kg/m³. ≈ 0.9 MWh/t; a 0.1 kg/s autoclave takes ≈ 320 kW from the shaft. Above ≈ 300 °C ethylene decomposes — burst disc (LDPE_DECOMPOSITION)
HDPE	loop_reactor	85–100 °C, 3–4 MPa in isobutane, catalyst_ziegler, H₂	polyethylene HDPE, 945–965 kg/m³
Polypropylene	loop_reactor	liquid propylene 70 °C, 3.5–4 MPa, Ziegler catalyst, ≥ 99.5 % propylene	polypropylene, isotacticity 95–98 %; poisons H₂O, CO, C₂H₂, O₂, S
PVC	balanced VCM process: direct chlorination (chlorination_reactor) + oxychlorination (catalyst_oxychlorination) + EDC cracking in a tube furnace; then suspension polymerization in batch_reactor	50–60 °C, 0.8–1.2 MPa, 6–8 physical hours, 85–90 % conversion. Pressure drops at ≈ 70 % — end of batch	pvc; residual VCM stripped in polymer_stripper to < 1 ppm or the lab rejects it; Ca/Zn stabilizer needed
SBR rubber	butadiene (extractive distillation, inhibited against popcorn polymer) + styrene in batch_reactor	emulsion, 5 °C, stop at 60 % conversion, 8–12 physical hours	synthetic_rubber; vulcanized in hot_press with sulfur and carbon_black (from pyrolysis_fuel_oil in the gasifier in carbon black mode)

polymer_extruder (Create shaft, heads pellets|pipe|sheet) makes pellets or products; stabilizer is added here, otherwise polymer_grade.stabilized = false and the part ages faster.

Application	Requirement	Consumer
0.4 kV cables	stabilized PVC	Energy Grid
6–35 kV cables	stabilized LDPE, MFI 0.2–2	Energy Grid
xlpe	LDPE MFI ≤ 2 → Co-60 irradiation 150 kGy → cross-link fraction ≥ 0.7, rated 90 °C	Isotopes and RTG → 6–220 kV cables
UF₆, HF, Cl₂ seals, linings	PTFE	fuel cycle, chemistry
Belts, water/steam seals ≤ 120 °C, hoses	vulcanized SBR	Create machines, mechanical_seal
Low-pressure water/gas pipe	HDPE	backlog
Acid pipe and tanks ≤ 60 °C	PVC	chemistry, metallurgy
Instrument housings A1–A2	bakelite	Player Content
Printed circuit boards	epoxy + epoxy_hardener	Player Content

Seal compatibility: SBR swells in hydrocarbons (leak rate ×5) and is destroyed by chlorine (×20); PTFE resists everything (×1) but creeps above 150 °C (×1.5); bakelite is for electrical use only.

Fluorine products

Step	Reaction / conditions	Block	Hazard
Chloromethanes	CH₄ + Cl₂ at 400–450 °C, series to CCl₄; recycle to maximize chloroform	chlorination_reactor	chloroform forms phosgene in light and air — store stabilized
R-22	CHCl₃ + 2 HF, SbCl₅ (catalyst_fluorination), 60–100 °C	batch_reactor	by-product R-23 (GWP 14,800) to the emissions ledger
TFE	2 CHClF₂ → C₂F₄ + 2 HCl, 700–800 °C, 25–35 % per pass	tube furnace, nickel-alloy coil	PFIB in heavy residue (worse than phosgene) — burn it
PTFE	suspension polymerization, persulfate, 40–90 °C	batch_reactor	TFE decomposition
PTFE parts	press and sinter at 370–380 °C	hot_press	—
ion_exchange_membrane	PTFE cloth + sulfonation	batch_reactor	—
sulfur_hexafluoride	S + 3 F₂, purification from very toxic S₂F₁₀	fluorination_reactor, caustic_scrubber	GWP 23,500: leaks from grid breakers are counted

TFE is stored inhibited at ≤ 0.7 MPa with O₂ < 20 ppm; without oxygen it can deflagrate (C₂F₄ → C + CF₄) from a hot spot or rapid filling.

Aromatics, resins and solvents

Ethylbenzene and styrene. Benzene + ethylene on zeolite (200–260 °C) → ethylbenzene; dehydrogenation at 600–640 °C on catalyst_styrene → styrene (60–70 % conversion). Diethylbenzene → divinylbenzene cross-linker. Styrene self-polymerizes above ≈ 60 °C in storage: inhibitor and cooling are required.

Ion-exchange resins. Styrene + 4–10 % DVB suspension copolymer beads (0.3–1.2 mm), then functionalized:

resin_spec type	Route	Capacity	Consumer
SAC strong acid cation	sulfonation with 98 % H₂SO₄	1.8–2.0 eq/L	water treatment (H-form), bisphenol A catalyst
SBA strong base anion	chloromethylation (carcinogenic chloromethyl ether) → trimethylamine	1.2–1.4 eq/L	uranium sorption, demineralization (OH-form)
CHELATING aminophosphonic	chloromethylation → NH₃ → Mannich reaction	2–3 g Ca/L	secondary brine purification

Resins track ionic form, capacity, oxidation (chlorine and ozone break cross-links), fouling and cycles. Example: SAC 1.9 eq/L, 60 % usable, hardness 2 meq/L → 570 bed volumes to breakthrough.

Phenol. Early path: carbolic fraction of coke-oven tar. Cumene path: benzene + crude FCC propylene → cumene → air oxidation to cumene hydroperoxide → acid cleavage → phenol + acetone (0.62 t acetone per t phenol). The hydroperoxide decomposes with runaway above 100–120 °C.

Bakelite. Novolak: phenol + formalin (F/P 0.75–0.85) + HCl in a batch_reactor under reflux, 95–100 °C. Adding all formalin at once gives ≈ 180 K adiabatic rise, so formalin is dosed by temperature (semi-batch). Molding powder bakelite_molding_powder = novolak + 10–15 % hexamine + wood flour (Create millstones) → hot_press 150–170 °C, 15–20 MPa → bakelite.

Epoxy. Propylene + Cl₂ → allyl chloride → chlorohydrins → epichlorohydrin; 2 phenol + acetone on SAC resin → bisphenol_a; BPA + excess ECH + NaOH → epoxy_resin. Hardener epoxy_hardener from EDC and ammonia.

Solvents. Acetone (cumene and ABE), butanol (ABE), methanol, chloroform. CCl₄, trichloroethylene, MEK and oxo alcohols are backlog.

Tributyl phosphate

Step	Process	Block
White phosphorus	Ca₃(PO₄)₂ + SiO₂ + C at 1400–1500 °C (≈ 13–14 MWh/t P); phosphate from minecraft:bone_meal	submerged_arc_furnace
PCl₃	P₄ + 6 Cl₂	chlorination_reactor
POCl₃	2 PCl₃ + O₂ (oxygen from air separation)	batch_reactor
Butanol (ABE)	fermentation of starch or sugar (potatoes, wheat, sugar cane), acetone:butanol:ethanol = 3:6:1, 48–72 physical hours at 35–37 °C	fermentation_vat + columns
TBP	POCl₃ + 3 BuOH → TBP + 3 HCl; vacuum HCl stripping, caustic wash, vacuum distillation	batch_reactor, column

tbp with a chem_lot (purity, DBP ppm) goes to the fuel cycle, where 30 % TBP in diluent_dodecane (from the refinery) becomes tbp_solvent for PUREX. DBP above 100 ppm binds Pu and U and spoils stripping. ABE fermentation bridges Minecraft farming and the nuclear fuel cycle.

Catalysts

ID	Composition	Use	Life and deactivation
catalyst_steam_reforming	Ni/α-Al₂O₃	SMR, methanator	3–5 years; sulfur, carbon at low S/C, sintering > 1000 °C
catalyst_shift_ht	Fe₃O₄-Cr₂O₃	HT shift	3–5 years; reduced at startup
catalyst_shift_lt	Cu-ZnO-Al₂O₃	LT shift	2–4 years; S, Cl irreversible; > 270 °C
catalyst_methanol	Cu/ZnO/Al₂O₃	methanol	2–4 years; sintering > 300 °C
catalyst_formaldehyde	silver gauze or Fe-Mo oxide	formaldehyde	Ag 3–6 months, recast
catalyst_acetylene_hydrogenation	Pd/Al₂O₃ (Pt fallback, selectivity ×0.7)	C₂H₂ removal	green oil → coke, steam-air regeneration
catalyst_oxychlorination	CuCl₂/Al₂O₃	oxychlorination	CuCl₂ loss, top-up
catalyst_styrene	Fe₂O₃/K₂O	styrene	1.5–2 years; potassium migration
catalyst_ziegler	TiCl₄/MgCl₂ + AlEt₃ (PYROPHORIC)	PP, HDPE	consumed into product
catalyst_fluorination	SbCl₅	R-22	Cl₂ top-up

All use the shared catalyst_state component defined for the refinery (Oil and Gas).

Chemical accidents (M10)

Scenario	Physics	What you design against it
Liquid Cl₂ leak	19.5 % flash at 25 °C plus aerosol; cloud 2.45× heavier than air, flows into low ground and basements; probit lethality (200 ppm × 30 min → 0.34)	gas_detector with Cl₂ cell, caustic_scrubber (1.13 kg NaOH per kg Cl₂), turn a leaking container so it leaks gas, not liquid
H₂ in chlorine	explosive at 4–89 % H₂, ignited by light and sparks	H₂-in-Cl₂ analyzer, CA_H2_IN_CL2_HIGH
Polymerization or condensation runaway	cooling or agitator failure, double initiator charge, all formalin at once	dual T and dT/dt monitoring, emergency cooling, short-stop inhibitor tank, relief sizing
Wrong bottom valve opened on a VCM reactor	Illiopolis 2004 prototype	"reactor under pressure → valve locked" interlock, bypass log (management of change)
TFE or LDPE ethylene decomposition	oxygen-free exothermic decomposition	storage pressure limit, O₂ analyzer, burst disc vented to a safe place
Cumene hydroperoxide decomposition	runaway	trips on temperature and concentration
Hydrogen fire	leaks from electrolyzers, PSA, lines	gas_detector, shutoff valves
PFIB, phosgene, S₂F₁₀	toxic impurities in residues	closed collection, incineration
Ammonium nitrate (backlog)	warehouse explosion	segregated storage, chem_lot control

Destruction is limited by server modes through DamageBudget (Multiplayer).

Hazards

Tag	Where
FLAMMABLE / EXPLOSIVE_MIX	methanol, styrene, aromatics, butanol, acetone / H₂, syngas, olefins, VCM, cracked gas
CHEMICAL_TOXIC	Cl₂, HCl, phosgene, PFIB, S₂F₁₀, white phosphorus, formaldehyde, VCM (carcinogen), chloromethyl ether
CHEMICAL_CORROSIVE	NaOH 32–50 %, hydrochloric acid, wet chlorine, PCl₃, POCl₃
OXIDIZER	ammonium nitrate; Cl₂ (steel burns in chlorine above ≈ 250 °C)
PYROPHORIC	white phosphorus, triethylaluminium
TOXIC_CO / ASPHYXIANT	syngas / purge nitrogen, CO₂, SF₆

Cross-industry links

Input	From
ethane, propane, butane, naphtha, sales_gas, FCC propylene, rock_salt, sulfur	Oil and Gas
benzene, toluene, xylenes, early phenol, coke, steel, pipe, Cu, Ni, Al, Pt, nitrogen, oxygen, treated water	Coal and Metallurgy
HF, F₂, H₂SO₄, HNO₃, NH₃, soda	Nuclear Fuel Cycle chemistry
electricity, rectifier_unit, busbar_dc, furnaces, steam	Energy Grid
submerged_arc_furnace	instrumentation / silicon tree (Player Content)

Output	Goes to
hydrogen	ammonia, reduction, refinery hydrotreating, Siemens polysilicon reactor
chlorine, sodium_hydroxide_solution	Zr chlorination, hydrometallurgy, cooling water chlorination, water treatment, FCC catalyst
hydrogen_chloride, hydrochloric_acid	trichlorosilane, steel pickling, resin regeneration
methanol, syngas	hydrate inhibitor in gas wells, ammonia
polyethylene, polypropylene, pvc, ptfe, synthetic_rubber, epoxy_resin, bakelite	cables, xlpe, UF₆/HF seals, belts, instrument housings, circuit boards
sulfur_hexafluoride	110–220 kV SF₆ breakers
ion_exchange_resin	uranium sorption, demineralization
tbp	PUREX solvent
ammonium_nitrate	mine blasting
acetone, cumene phenol	lube oil extraction, electronics
emissions: SMR CO₂, R-23, SF₆, VCM, Cl₂	Environment and Economy

See also

• Oil and Gas — feedstocks, catalyst rules, columns and compressors
• Nuclear Fuel Cycle — TBP, resins, PTFE seals
• Isotopes and RTG — XLPE by irradiation
• Automation Platform — sequence control, safety instrumented systems
• Operations and Safety — maintenance panel faults, management of change
• Accidents