Epichlorohydrin from Propylene (Allyl Alcohol Intermediate)
Epichlorohydrin Production Costs Report | Issue C | Q4 2024
| Report Details |
| 110 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 110 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 study presents a techno-economic analysis of Epichlorohydrin production from propylene and chlorine in the United States. In this process, propylene is subjected to an acetoxylation reaction, followed by hydrolysis, generating allyl alcohol, which is then chlorinated, yielding glycerol dichlorohydrins. Finally, the glycerol dichlorohydrins generated are reacted with calcium hydroxide, yielding Epichlorohydrin.
The report provides a comprehensive study of Epichlorohydrin production and related Epichlorohydrin production cost, covering three key aspects: a complete description of the Epichlorohydrin production process examined; an in-depth analysis of the related Epichlorohydrin plant capital cost (Capex); and an evaluation of the respective Epichlorohydrin plant operating costs (Opex).
The Epichlorohydrin 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 Epichlorohydrin 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 Epichlorohydrin 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 two major sections: (1) Allyl Alcohol Synthesis; and (2) Epichlorohydrin (ECH) Production.
Allyl Alcohol Synthesis. Propylene is mixed with acetic acid and oxygen. The mixture, in the vapor phase, is passed through a fixed palladium-based catalyst bed, where the formation of allyl acetate takes place. The reactor effluent comprises allyl acetate, unreacted feeds and carbon dioxide formed by side reactions. The effluent is divided into a gaseous and a liquid stream. The gases (mostly unreacted oxygen and propylene), also containing CO2, are routed to a CO2 Removal system and then recycled to the reactor inlet. The liquid portion of the reaction effluent is transferred to the Hydrolysis reactor, where allyl acetate is converted into allyl alcohol and acetic acid. The hydrolysis product is treated in the allyl alcohol purification system, where unreacted allyl acetate and acetic acid are recovered and recycled to the hydrolysis reactor and acetoxylation reactor, respectively. An aqueous solution of allyl alcohol is transferred to the Epichlorohydrin synthesis section.
Epichlorohydrin Production. Aqueous allyl alcohol, hydrochloric acid, and gaseous hydrogen chloride are mixed and fed to the chlorination reactors, where 2,3-dichloro-1-propanol is obtained. Reaction effluent is sent to the Hydrogen Chloride Recovery column, where hydrogen chloride is recovered both as dry vapors and aqueous solution. 2,3-dichloro-1-propanol is then fed to the saponification reactor along with a calcium hydroxide slurry. The saponification reaction results in Epichlorohydrin and calcium chloride, which is removed in by means of a distillation column downstream. Finally, light and heavy impurities are separated through a last distillation step, and high-purity Epichlorohydrin is obtained.
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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 Epichlorohydrin 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 Epichlorohydrin 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 Epichlorohydrin 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 Epichlorohydrin 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
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This report presents a economic analysis of Epichlorohydrin production from allyl chloride and chlorine in the United States using a typical hypochlorination process. Initially, allyl chloride is reacted with hypochlorous acid, formed by chlorine dispersion in water. The glycerol dichlorohydrins generated are then treated with calcium hydroxide to promote epoxidation, yielding ECH.
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Epichlorohydrin from Propylene (Allyl Chloride Intermediate)
This feasibility study provides an economic analysis of Epichlorohydrin (ECH) production from propylene and chlorine in the United States. Initially, propylene is chlorinated, generating allyl chloride, which is reacted with hypochlorous acid, formed by chlorine dispersion in water. Finally, the glycerol dichlorohydrins generated are hydrolyzed with calcium hydroxide, yielding ECH.
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