Propylene Oxide Production from Propylene and Hydrogen Peroxide
Propylene Oxide Production Costs Report | Issue D | Q4 2024
| Report Details |
| 450 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 450 kta (kilo metric ton per annum) United States-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.
Report Abstract
This report presents the economics of Propylene Oxide (PO) production from polymer grade (PG) propylene and hydrogen peroxide in the United States, similar to the hydrogen peroxide to propylene oxide (HPPO) process jointly developed by Evonik and Uhde.
The report provides a comprehensive study of Propylene Oxide production and related Propylene Oxide production cost, covering three key aspects: a complete description of the Propylene Oxide production process examined; an in-depth analysis of the related Propylene Oxide plant capital cost (Capex); and an evaluation of the respective Propylene Oxide plant operating costs (Opex).
The Propylene Oxide production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The Propylene Oxide plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The Propylene Oxide plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Process Schematic
The process under analysis comprises three major sections: (1) Epoxidation; (2) Raw Materials Recovery; and (3) Purification.
Epoxidation. Fresh propylene, along with propylene recovered downstream and hydrogen peroxide, are fed to fixed-bed reactors, where the epoxidation takes place in the presence of titanium silicate catalysts. Fresh and recovered methanol, used as reaction solvent, are also fed to the reactors.The reaction is carried out in the liquid phase, at elevated pressures and moderate temperatures. The reactors are operated alternatively: while one is in operation, the other is in regeneration mode. More than 95% of the propylene is converted to Propylene Oxide. The epoxidation yields a mixture containing the Propylene Oxide product and water as co-product, but also unreacted propylene, methanol and residual amounts of impurities such as glycol ethers.
Raw Materials Recovery. The epoxidation effluent is passed subsequently through a flash vessel and two distillation columns for unreacted propylene and methanol recovery. Each raw material is sent to a different column in order to remove impurities and is recycled to epoxidation.
Purification. The crude PO is directed to a extractive system composed of two distillation columns, in which most hydrocarbon contaminants are stripped off, using an aqueous solution of tert-butyl alcohol. The bottom product of the system is fed to a last column, which further purifies the Propylene Oxide from impurities.
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Production Process Information
Process Consumptions
Labor Requirements
Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
Plant Capital Cost Details
Operating Cost Details
Plant Cost Breakdowns
Plant Capacity Assessment
Process Flow Diagrams
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Propylene Oxide production plant examined
Plant Capital Cost Details
Detailing of fixed capital (ISBL, OSBL & Owner’s Cost), working capital and additional capital requirements
Plant Cost Breakdowns
Breakdown of Propylene Oxide process unit (ISBL) costs and infrastructure (OSBL) costs; plant cost breakdown per discipline
Operating Costs Summary
Summary presenting the operating variable costs and the total operating cost of the Propylene Oxide production plant studied
Operating Cost Details
Detailing of utilities costs, operating fixed costs and depreciation
Plant Capacity Assessment
Comparative analysis of capital investment and operating costs for different Propylene Oxide plant capacities
Production Process Information
Block Flow Diagram, descriptions of process unit (ISBL) and site infrastructure (OSBL)
Process Consumptions
Raw materials and utilities consumption figures, by-products credits, labor requirements
Process Diagrams
Process flow diagrams (PFD), equipment list and industrial site configuration
Other Propylene Oxide Production Cost Reports
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This report examines the costs related to Propylene Oxide (PO) production from chemical grade (CG) propylene and isobutane in the United States. The process is similar to LyondellBasell process. In this process, isobutane is oxidized to produce t-butyl hydroperoxide, which reacts with propylene to produce PO.
Details: 450 kta United States-based plant | Q4 2024 | 107 pages | Issue E From $1,199 USD
The cost analyses presented in this report target a 450 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.
Propylene Oxide from Propylene and Hydrogen (Indirect Oxidation)
This report analyses the economics of Propylene Oxide (PO) production from polymer grade (PG) propylene and hydrogen in the United States. The process used is a direct epoxidation similar to AIST/Nippon Shokubai process. Initially, hydrogen is directy oxidized with oxygen to hydrogen peroxide. The peroxide converts propylene into propylene oxide.
Details: 250 kta United States-based plant | Q4 2024 | 107 pages | Issue G From $1,199 USD
The cost analyses presented in this report target a 250 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.
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