Commodity Production Costs Report
Propylene Oxide Production from Propylene and Ethylbenzene
Propylene Oxide Operating Costs & Plant Construction Costs
This study presents the economics of Propylene Oxide (PO) production from chemical grade (CG) propylene and ethylbenzene in the United States. In the process under analysis, ethylbenzene is oxidized to ethylbenzene hydroperoxide, which then reacts with propylene to yield PO. Styrene is generated as by-product in the process.
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.
Key reference(s): ?

The process under analysis comprises 3 major sections: (1) Propylene Oxide (PO) Production; (2) PO Purification; and (3) Styrene Synthesis.
PO Production. The production of PO is based on two reactions. First, ethylbenzene is peroxidized with air in liquid phase yielding a solution of ethylbenzene hydroperoxide in ethylbenzene. This conversion is restricted to 10%. Then, this solution peroxidizes chemical grade propylene with molybdenum catalyst under high pressure, yielding propylene oxide. The epoxidation yields up to 99% reactant with 92-96% selectivity to PO.
PO Purification. Crude PO stream from PO production is fed to a series of columns, where C3s, phenyl ethanol, ethylbenzene, and other hydrocarbon impurities are removed. 99.9 wt% Propylene Oxide is obtained. The C3 stream is further separated into propane, used as fuel, and propylene, recycled to epoxidation. A stream containing phenyl ethanol, ethylbenzene, remaining reagents and other by-products is directed to next section.
Styrene Synthesis. The mixture is purified by means of four distillation columns. Residual ethylbenzene from such stream is removed, condensed and recycled to the Peroxidation, and impurities withdrawn are separated and burned for fuel. The stream rich in 1-phenylethanol and still containing acetophenone is fed to a dehydration reactor, where it is converted to styrene in the presence of an alumina catalyst. To increase the overall process economics, acetophenone, the main by-product from epoxidation, is extracted during the purification of the styrene and directed to a hydrogenation step, promoted by a copper-based catalyst, in which it is converted to 1-phenylethanol. The product stream is then recycled to the dehydration reactor, thus increasing styrene production.
Report in PDF Format
Download & Explore Anytime
Access in Various Devices
Print & Read Comfortably
Share With Co-workers
Up-to-date Report
Professional report based on Q3 2024 economic data, ensuring timely evaluations.
Multiple Use Cases
Ideal for investment screening, feasibility studies, cost estimates, and research planning.
Proven Methodology
Developed using a consistent methodology honed over a decade, ensuring reliable cost analyses.
Report Editions
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
Other Propylene Oxide Production Cost Reports

Propylene Oxide Production from Propylene and Cumene
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.
Details: 450 kta United States-based plant | Q3 2024 | 107 pages | Issue C | From $1,199 USD

Propylene Oxide Production from Propylene and Hydrogen Peroxide
This report presents the economics of Propylene Oxide (PO) production from polymer grade (PG) propylene and hydrogen peroxide in the United States, similar to the hydrogen peroxide to propylene oxide (HPPO) process jointly developed by Evonik and Uhde.
Details: 450 kta United States-based plant | Q3 2024 | 107 pages | Issue D | From $1,199 USD

Propylene Oxide Production from Propylene and Isobutane
This report examines the costs related to Propylene Oxide (PO) production from chemical grade (CG) propylene and isobutane in the United States. The process is similar to LyondellBasell process. In this process, isobutane is oxidized to produce t-butyl hydroperoxide, which reacts with propylene to produce PO.
Details: 450 kta United States-based plant | Q3 2024 | 107 pages | Issue E | From $1,199 USD
Could Not Find the Report You Need?
Obtain a Bespoke Report
Get a report targeting the process in which you are interested
See Offer Details
Understand Bespoke Reports and how you can easily order them
Check Editions & Pricing
Complete a brief form and see a quotation for your Bespoke Report
Other Related Production Cost Reports

Hydrogen Production from Natural Gas (Partial Oxidation Process)
This study provides a techno-economic study of Hydrogen production from natural gas in the United States. In this analysis, natural gas is submitted to a thermal partial oxidation process, producing syngas, which is passed through a shift converter to enrich the Hydrogen output.
Details: 25 MM Nm3/y United States-based plant | Q3 2024 | 107 pages | Issue C | From $799 USD

Ethylbenzene from Benzene and Ethylene (CD Process)
This study provides a techno-economic analysis of a catalytic distillation (CD) process similar to CDTECH for Ethylbenzene production from benzene and dilute ethylene in the United States. This process combines the catalytic alkylation and distillation in a single operation.
Details: 600 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $799 USD

Butanediol Production from Propylene Oxide
This report shows a techno-economic analysis related to the construction of a plant in the United States for 1,4-Butanediol (BDO) production from propylene oxide using a process similar to LyondellBasell. Initially, propylene oxide is isomerized to allyl alcohol. The allyl alcohol then reacts with syngas, generating 4-hydroxybutyraldehyde, which is finally hydrogenated to BDO.
Details: 100 kta United States-based plant | Q3 2024 | 107 pages | Issue G | From $799 USD

Hydrogen Production from Natural Gas (Steam Reforming)
This report provides an economic analysis of Hydrogen production from natural gas in the United States using a steam reforming process. Initially, methane present in natural gas is cracked with steam generating syngas. Then, the carbon monoxide from syngas is reacted with steam, producing carbon dioxide and additional hydrogen.
Details: 1000 MM Nm3/y United States-based plant | Q3 2024 | 107 pages | Issue A | From $799 USD

Ethylbenzene from Benzene and Ethylene (Zeolite Catalyst)
This report presents the economics of a liquid-phase alkylation process similar to Polimeri Europa using zeolite catalyst for Ethylbenzene production from benzene and polymer grade ethylene in the United States.
Details: 850 kta United States-based plant | Q3 2024 | 107 pages | Issue A | From $799 USD

Propylene Glycol from Propylene Oxide
This report analyses the economics of Propylene Glycol production from propylene oxide in the United States, via a typical hydration process. In this analysis, propylene oxide is hydrolyzed to propylene glycol. Dipropylene glycol is produced as by-product.
Details: 200 kta United States-based plant | Q3 2024 | 107 pages | Issue D | From $799 USD
+800 Reports Developed, Targeting +250 Commodities
Vast Report Library
858 independent and up-to-date reports examining embryonic and established production processes.
Free Sample Reports
Quickly understand the structure and depth of content of our professional reports.