Commodity Production Costs Report

Propylene Oxide Production from Propylene and Isobutane

Propylene Oxide Operating Costs & Plant Construction Costs

450 kta United States-based plant | 107 Pages | Issue E | Q3 2024
Starting at $1,199 USD | See Report Editions Prices

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.

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): ?

Propylene Oxide Production Cost Report Process Schematic

The process under analysis comprises two major sections: (1) Reactions; and (2) Purification.

Reactions. Isobutane is reacted with oxygen yielding a solution of tertiary butyl hydroperoxide (TBHP) and tertiary butyl alcohol (TBA) by-product. While the reaction is exothermic, reaction conditions are regulated such that the reaction mixture is constantly boiling, so that reaction heat is removed by reaction media vaporization. Accordingly, the oxidation product - a vapor mixture - is removed from the reactor and cooled, in such a way that TBHP, TBA, unreacted isobutane and other readily condensable components are condensed and partially routed to an isobutane recovery step and then to epoxidation reaction system. The second reaction, epoxidation, occurs by mixing the peroxide solution in TBA with propylene. The reaction is carried out in the liquid phase, in the presence of a homogeneous molybdenum catalyst, yielding Propylene Oxide (PO). As in the peroxidation, the heat of epoxidation reaction is removed by the medium vaporization. The epoxidation product is then separated into a distillate stream containing unreacted propylene, propylene oxide and TBA, and a heavy organic stream, comprising high boiling by-products and dissolved molybdenum catalyst. The catalyst-rich stream is submitted to a thermal treatment before being recycled to epoxidation.

Purification. The distillate from epoxidation reaction system is sent to the propylene column, which strips off propylene, propane and residual light ends from the epoxidation effluent stream. The C3 stream is further treated in a column for recovery of a propylene-rich stream that can be recycled to the epoxidation. The C3-free epoxidation product, in turn, is fed to the TBA recovery, where a crude PO stream is obtained after a TBA-rich stream is separated, treated for impurities removal, and recycled to the epoxidation reaction. The crude PO stream is further purified by means of an extractive distillation process followed by another distillation column, from which high-purity Propylene Oxide is obtained as overheads product.

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

Compact

 

$1,199

USD

Select

Table of Contents


Features
  • Production Process Information
  • Process Consumptions
  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
  • Production Costs Datasheet
  • See All Features

 80 Pages | 22 Tables | 9 Images

Read-only Online PDF Format

Updated with Q3 2024 Data

Detailed

 

$1,999

USD

Select

Table of Contents


Features
  • Production Process Information
  • Process Consumptions
  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
  • Production Costs Datasheet
  • Plant Capital Cost Details
  • Operating Cost Details
  • See All Features

 90 Pages | 28 Tables | 13 Images

Downloadable PDF Format

Updated with Q3 2024 Data

Most Popular
Premium

Starting at

$3,399

USD

Select

Table of Contents


Features
  • 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
  • Costs in Different Countries Add-on
  • See All Features

  • 107 Pages | 34 Tables | 22 Images
  • Print-enabled PDF Format Add-on
  • Updated with Q3 2024 Data
  • Share with Co-workers
  • Technical Support via Email

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

Preview our Production Cost Reports

Other Propylene Oxide Production Cost Reports

Look Inside
Propylene Oxide Production from Propylene and Ethylbenzene

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.

Details: 450 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $1,199 USD

Look Inside
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

Look Inside
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

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

Look Inside
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

Look Inside
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

Look Inside
Isobutane Production

This report examines the costs incurring from producing Isobutane via catalytic isomerization of n-butane. n-Butane is dehydrogenated to 1-butene, which is then rearranged to isobutylene. Finally, isobutylene is hydrogenated producing isobutane. The economic analysis provided assumes a plant located in the United States.

Details: 850 kta United States-based plant | Q3 2024 | 107 pages | Issue A | From $999 USD

+800 Reports Developed, Targeting +250 Commodities

Best-in-Class Reports

Analysis of capital and operating costs of commodity production processes.

Learn More

Vast Report Library

858 independent and up-to-date reports examining embryonic and established production processes.

Browse Library

Free Sample Reports

Quickly understand the structure and depth of content of our professional reports.

See Full Samples