Commodity Production Costs Report
Epichlorohydrin from Propylene (Allyl Chloride Intermediate)
Epichlorohydrin Operating Costs & Plant Construction Costs
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.
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.
Key reference(s): ?
The process under analysis comprises three major sections: (1) Allyl Chloride Reaction; (2) Propylene Recovery; and (3) Epichlorohydrin (ECH) Production.
Allyl Chloride Reaction. Initially, chemical grade propylene is preheated, mixed with chlorine and fed to a reactor where the chlorination reaction is carried out in the vapor phase, generating allyl chloride and some by-products. The chlorination products are cooled and then directed to the Prefractionator, where a stream rich in organic chlorides is separated from unreacted propylene and hydrogen chloride. The organic chlorides are routed to two distillation columns for the removal of light-end impurities and heavy-end impurities.
Propylene Recovery. The distillate from the Prefractionator is washed countercurrently with water in an absorber, in such a way that the hydrogen chloride is absorbed forming a hydrogen chloride solution, removed from column bottom. The gaseous stream from the overhead of the absorber upstream is fed to a Caustic Scrubber, where residual hydrogen chloride is removed. The washed propylene gas is compressed in a multi-stage compressor and then recycled to preheating.
Epichlorohydrin Production. The allyl chloride stream is reacted with hypochlorous acid, formed in turn by chlorine dispersion in water. The chlorohydrination reaction is conducted in the liquid phase, adiabatically. The liquid product from this reaction is passed through a separator where an aqueous phase, containing hypochlorous acid, is recycled, and a hydrocarbon phase, containing glycerol dichlorohydrins, is reacted with calcium hydroxide, yielding Epichlorohydrin product. The crude ECH stream is routed to one stripper and two distillation columns for the removal of calcium chloride, light-end impurities and heavy-end impurities.
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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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Other Epichlorohydrin Production Cost Reports
Epichlorohydrin from Propylene (Allyl Alcohol Intermediate)
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.
Details: 110 kta United States-based plant | Q3 2024 | 107 pages | Issue C | From $1,199 USD
Epichlorohydrin Production from Glycerol and Hydrogen Chloride
This study provides an economic analysis of Epichlorohydrin production from glycerol in the United States. Initially, glycerol is reacted with hydrogen chloride in a hydrochlorination reaction, generating dichlorohydrins (DCH). Then, the DCH is hydrolyzed by caustic soda, yielding epichlorohydrin (ECH).
Details: 100 kta United States-based plant | Q3 2024 | 107 pages | Issue D | From $799 USD
Epichlorohydrin Production from Acrolein
This report provides a techno-economic study of an early stage process for Epichlorohydrin production from acrolein in the United States. The process examined is a non-commercial route based on Dow Chemical patents.
Details: 75 kta United States-based plant | Q3 2024 | 107 pages | Issue E | From $799 USD
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