Commodity Production Costs Report
Isopropyl Alcohol Production from RG Propylene
Isopropanol Operating Costs & Plant Construction Costs
This report presents the economics of Isopropyl Alcohol production from refinery grade (RG) propylene via a typical indirect propylene hydration process. In this process, RG propylene reacts with sulfuric acid to form isopropyl alcohol sulfates. Those sulfates are then reacted with water to form Isopropanol. The study assumes a plant located in the United States.
The report provides a comprehensive study of Isopropanol production and related Isopropanol production cost, covering three key aspects: a complete description of the Isopropanol production process examined; an in-depth analysis of the related Isopropanol plant capital cost (Capex); and an evaluation of the respective Isopropanol plant operating costs (Opex).
The Isopropanol 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 Isopropanol 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 Isopropanol 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 is comprised of three major sections: (1) Isopropanol synthesis; (2) propylene recovery; and (3) purification.
Isopropanol synthesis. Refinery grade (RG) propylene (70 wt%) is converted into Isopropanol through two consecutive reaction steps. First, gaseous propylene is contacted with weak sulfuric acid in a reactive absorber, forming isopropyl sulfates. Then, the sulfates are hydrolyzed by steam addition in a stripper reactor, generating isopropanol. The stripper gaseous product is absorbed in caustic solution for residual acid neutralization and sent to the purification section. The stripper liquid effluent, containing dilute sulfuric acid, is treated in an acid reconcentration unit for further reuse in the process.
Propylene recovery. The reactive absorber gaseous effluent is treated in a caustic scrubber for residual acid removal and fed to a column for recovery of unreacted propylene. Propane contained in the RG propylene is withdrawn from this column as oveheads product and purged from the process. Recovered propylene is recycled to the Isopropanol synthesis section.
Purification. The crude isopropanol from both the caustic scrubber and the stripper reactor are directed to an ether separation step, where diisopropyl ether (generated in side reactions) is separated and recycled to the absorber reactor to react with sulfuric acid, forming sulfate and isopropanol. The ether-free crude isopropanol is transferred to the alcohol column for removal of high boiling impurities. The overheads product from alcohol column comprises an azeotropic mixture of isopropanol and water. Finally, dry isopropanol is produced after dehydration by means of azeotropic distillation using diisopropyl ether as azeotroping agent.
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Professional report based on Q3 2024 economic data, ensuring timely evaluations.
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Isopropanol 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 Isopropanol 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 Isopropanol 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 Isopropanol 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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