Steam Cracking: Where Everyday Plastics Begin
At first glance, a plastic bottle, a smartphone display, or food packaging may seem far removed from heavy industry. But behind these everyday items lies a fascinating starting point: the steam cracker.
In Europe alone, steam crackers have a total production capacity of around 23 million tons per year (as measured by ethylene). That is enough to produce over 230 billion 1-liter plastic bottles, or the weight of about 230,000 fully loaded freight wagons. This immense output forms the foundation for countless products we use every day, from packaging and household goods to automotive parts and electronics. Steam crackers are, quite literally, where much of our modern material world begins.
The Heart of Petrochemistry
Steam cracking is one of the most important processes in the petrochemical industry. In this high-temperature procedure, large hydrocarbon molecules are broken down into smaller, highly reactive ones: the “building blocks” for modern materials.
Among the most valuable products are ethylene and propylene, which serve as the starting point for plastics, synthetic fibers, solvents, and many other chemical products.
The process is anything but gentle. Extreme heat and rapid cooling occur within seconds, placing enormous demands on every piece of equipment involved.
From Naphtha to Key Chemicals
Most European steam crackers use naphtha as their primary feedstock. Naphtha is a light, flammable fraction obtained from crude oil refining, consisting mainly of various hydrocarbons. When processed in a steam cracker, it produces a precise mix of valuable chemicals:
∙ Ethylene (28.7%): used for polyethylene, PVC, polystyrene
∙ Propylene (16.1%): for polypropylene, chemical intermediates, flame cutting
∙ Hydrogen, methane, butadiene, butene, and pyrolysis gasoline – each with their own industrial roles
From ethylene alone, the main derivatives include:
∙ Polyethylene (56%): the world’s most widely used plastic
∙ Ethylene dichloride (14%): key for PVC
∙ Ethylene oxide (11%): for antifreeze, detergents, and more
∙ Ethylbenzene (7%): precursor to polystyrene
Why Propylene Matters
While propylene is best known as the basis for polypropylene, its applications extend far beyond plastics. It plays a role in flame cutting, the production of bleaching agents, and even in materials for electronics, such as polypropylene films used in smartphone displays.
Four Temperature Zones, One Challenge
A steam cracker works in distinct temperature stages ranging from 150 °C to over 800 °C. Each stage triggers specific chemical reactions and exposes gaskets and other components to constant high mechanical and thermal loads.
Revoseal: Sealing Reliability at Every Stage
At Revoseal Europe GmbH, we provide high-performance gaskets that deliver reliable sealing across all these demanding process zones.
Our solutions not only meet extreme technical requirements, they also streamline operations. In many cases, we replace a large variety of standard gaskets with only two specialized types, reducing complexity, downtime, and maintenance costs.
From crude oil to consumer goods, the journey of modern materials begins in the steam cracker. With Revoseal sealing technology, this journey becomes safer, more efficient, and more reliable. Every step of the way.
