Propylene Oxide Production from Propylene and Chlorine
Propylene Oxide Production Costs Report | Issue A | Q3 2024
Report Details |
450 kta United States-based plant | Q3 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 chemical grade (CG) propylene and chlorine in the United States. In the process under analysis, propylene and chlorine react, yielding chlorohydrin intermediate, which is then dehydrochlorinated to produce PO. Dichloropropane is generated as by-product.
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) Hypochlorination; (2) Epoxidation; and (3) Purification.
Hypochlorination. Initially, fresh, gaseous polymer grade propylene and chlorine are mixed with water, forming an aqueous solution. Such compounds react producing propene – chloronium complex, an intermediate which reacts with water yielding hydrochloric acid and propylene chlorohydrin (PCH) isomers. The gaseous effluent from the reactor is fed to a separator, which separates a solution containing PCH from the vent gas. The PCH solution is directed to the Epoxidation, while the vent gas is passed through a caustic scrubber and released.
Epoxidation. The PCH solution and a caustic solution (from a chlor-alkali unit) are fed to a saponifier, where a dehydrochlorination reaction takes place. Here, the PCH is converted to propylene oxide (PO) while organic impurities are stripped from the brine. The brine from saponifier bottom is directed to a treatment step, while a stream containing PO from saponifier overhead is routed to purification steps.
Purification. The stream rich in PO is distilled in a first column for obtaining a crude propylene oxide stream, removed from overhead. A solution containing 1,2-dichloropropane (DCP) from column bottom is decanted, yielding a DCP-rich stream and water. In a second column, residual light ends are stripped off from the crude PO stream and burned for fuel. The column’s bottom product is fed to a third column, which further purifies the PO from impurities. A 99.9 wt% Propylene Oxide is condensed and stored. Heavy ends are burned for fuel. The DCP-rich stream is treated for the neutralization, and for the removal of epoxidation by-products and other heavy components. The brine stream from Epoxidation and the wastewater from the first column are treated and returned to the chlor-alkali facility.
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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
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