Propylene Oxide Production from Propylene and Cumene
Propylene Oxide Production Costs Report | Issue C | Q2 2024
Report Details |
450 kta United States-based plant | Q2 2024 | 107 pages | Delivered in PDF |
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 analyses the economics of Propylene Oxide (PO) production from chemical grade (CG) propylene and cumene in the United States, similar to Sumitomo process. In the process under analysis, cumene is oxidized to cumene hydroperoxide, which in then reacted with propylene to yield PO.
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) Product Formation; (2) Product Purification; and (3) Cumene Recovery.
Product Formation. Fresh and recovered cumene is fed, along with air, to column reactors, where an oxidation reaction takes place. A sodium carbonate solution is also fed to the reaction media to control pH. The cumene hydroperoxide (CHP) effluent is routed to a separator vessel, where the carbonate solution is removed, and dissolved air is flashed off. The CHP is concentrated in an evaporator, and directed to the Epoxidation reactor, where it reacts with fresh and recovered polymer grade (PG) propylene, yielding propylene oxide (PO) and dimethyl benzyl alcohol (DMBA). The epoxidation effluent is separated in a liquid and a gaseous stream in a flash vessel, which are sent to the Depropenizer columns.
Product Purification. The liquid and gaseous epoxidation effluents are fed to low-pressure and high-pressure distillation columns, respectively. Propylene, propane and light ends are removed as overheads products from these columns. The C3’s stream from the high-pressure column is routed to the Propane Splitter, which separates propylene from propane, which is burned as fuel. The propylene is mixed with the overhead stream from the low-pressure column and returned to the Epoxidation reactor. The bottom products of the columns are mixed and routed to Crude PO Separation, where PO is separated from unreacted cumene and DMBA, which are directed to cumene recovery. The PO is further purified in PO purification and PO product column, obtaining a 99.9 wt% PO.
Cumene Recovery. The bottom of PO crude separation is fed to cumene recycle column, which separates cumene, recycled to Peroxidation, from DMBA, which is sent to purification, yielding high purity DMBA, that is then is directed to a hydrogenolysis reactor. In this step, DMBA reacts with hydrogen, generating cumene, which is sent to purification and then recycled to Epoxidation.
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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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