Propylene Production from Propane (Oxydehydrogenation)
Propylene Production Costs Report | Issue D | 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
The report under analysis presents the economics of Polymer Grade (PG) Propylene production from propane in the United States. The process examined in this report uses a two-step dehydrogenation process (steam reforming/oxyreaction), similar to Uhde STAR.
The report provides a comprehensive study of Propylene production and related Propylene production cost, covering three key aspects: a complete description of the Propylene production process examined; an in-depth analysis of the related Propylene plant capital cost (Capex); and an evaluation of the respective Propylene plant operating costs (Opex).
The Propylene 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 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 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 four major sections: (1) Reaction; (2) CO2 Separation; (3) Gas Separation; and (4) Fractionation.
Reaction. Propane is fed into a depropanizer column to heavy impurities removal. The depropanizer distillate is vaporized, mixed with steam, and pre-heated before entering the reformer, where most of the propane conversion takes place. Next, the effluent is fed to the oxyreactor, where hydrogen is selectively combusted by oxygen. The process gas is cooled in a series of heat exchanges to recover heat to be utilized in the process and is compressed.
CO2 separation. The compressed gas is fed to an absorption column, where CO2 is removed in the bottoms by washing with an aqueous piperazine activated methyldiethanolamine (MDEA) solution. This stream is depressurized, liberating gases that are recycled to the absorption column. The CO2-rich liquid solution from the flash vessel is fed to the solvent regeneration column, which separates CO2 in the overheads and the MDEA solution in the bottoms, which is recycled to the absorption column.
Gas separation. The overhead stream of the absorption column is dried in a molecular sieve and fed to a low-temperature separation system (cold box) for the removal of lights. In this system, a hydrogen-rich stream is also obtained, which is purified in a pressure swing adsorber (PSA) unit to obtain high purity hydrogen byproduct.
Fractionation. The liquid fraction from the cold box is sent to the fractionation area, which consists of a deethanizer column for removal of lights and a P-P splitter, where polymer grade propylene is obtained. Unconverted propane from the P-P splitter bottoms is recycled to the reaction area.
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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 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 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 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 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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