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Contents
1
Introduction
1-1
2
Summary
2-1
Commercial aspects
2-1
Global propylene industry
2-1
China
2-2
North America
2-3
Propane dehydrogenation
2-3
Propylene prices
2-5
Technical aspects
2-6
Chemistry
2-7
Catalysts
2-7
Reactor systems
2-8
CB&I Lummus CATOFIN PDH process
2-9
UOP Oleflex PDH process
2-10
Uhde STAR PDH process
2-11
Economic aspects
2-12
Propylene from propane by the Lummus CATOFIN process
2-12
Propylene by the UOP Oleflex process
2-13
Propylene from propane by the Uhde STAR process
2-13
Confidence ratings
2-14
Conclusions
2-14
3
Industry status
3-1
Propylene grades for chemical manufacture
3-1
Global propylene industry
3-2
China
3-3
North America
3-5
Propylene production
3-6
Steam cracking
3-6
Refinery FCC
3-7
Propane dehydrogenation
3-7
Metathesis
3-8
Propylene transportation and storage
3-9
Propylene prices
3-9
Commercial-scale PDH plants
3-10
North America
3-11
China
3-12
Thailand
3-13
Malaysia
3-13
South Korea
3-13
Middle East
3-13
Europe
3-14
Africa
3-14
CIS and Baltic States
3-14
4
Technology review
4-1
Propylene by propane dehydrogenation (PDH)
4-1
Chemistry
4-2
Commercial processes
4-3
The UOP Oleflex process
4-4
IHS CHEMICAL | Process Economics Program RP267A
October 2015
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© 2015 IHS
Chemistry of the Oleflex process
4-4
Development of dehydrogenation catalysis by UOP
4-7
Pt–based catalysts
4-7
Other PDH catalysts from UOP
4-9
Oleflex reactor/regenerator system
4-9
Oleflex process
4-13
Alternative UOP reactor and process schemes for PDH
4-15
Fluidized bed reactors
4-15
Integration of Oleflex with FCC
4-17
Oxidative dehydrogenation
4-17
The CB&I/LUMMUS CATOFIN process
4-18
Chemistry of the CATOFIN process
4-18
CATOFIN reactor, regeneration, and heat management system
4-19
Development of CATOFIN dehydrogenation catalysis and process
4-20
CATOFIN process configuration
4-22
The Uhde STAR process
4-24
Chemistry of the STAR process
4-24
Development of dehydrogenation catalysis by Phillips Petroleum
4-29
Reactor system for oxydehydrogenation
4-34
Feedstock for the STAR process
4-36
Configuration and operating conditions of the STAR process
4-37
Linde/BASF/Statoil/Borealis PDH process
4-38
FBD–3 process
4-39
5
Propylene from propane by the CATOFIN process
5-1
Process description
5-1
Propane dehydrogenation
5-1
Product separation
5-2
Compression and low temperature gas separation
5-2
Recovery and purification of propylene
5-3
Refrigeration
5-4
Process discussion
5-4
Catalyst and chemicals
5-5
Low temperature gas separation
5-6
Steam system configuration
5-6
Materials of construction
5-6
Integration with a polypropylene plant
5-7
Process economics
5-11
Capital cost
5-11
Production cost
5-11
Profitability
5-12
6
Propylene from propane by the Oleflex process
6-1
Process description
6-1
Propane dehydrogenation (Section 100)
6-2
Feed treatment and heavies removal
6-2
PDH reaction and continuous catalyst regeneration
6-2
Transfer of catalyst between PDH reactors
6-3
Continuous catalyst regeneration
6-3
Product recovery (Section 200)
6-5
Gas separation and hydrogen purification
6-5
SHP and fractionation
6-5
Process discussion
6-6
IHS CHEMICAL | Process Economics Program RP267A
October 2015
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© 2015 IHS
Feedstocks and products
6-7
Catalyst
6-7
Reactor-regenerator
6-8
SHP reactor
6-9
C3 splitter heat pump design
6-9
Materials of construction
6-9
Environmental and safety aspects
6-9
PDH reactor regeneration vent gas
6-9
PDH catalyst
6-10
Dryer regeneration off-gas
6-10
Process economics
6-18
Capital cost
6-18
Production cost
6-18
Profitability
6-19
7
Propylene from propane by the Uhde STAR process with oxydehydrogenation
7-1
Process description
7-1
Feed pretreatment and reaction section
7-1
Feed treatment and heavies removal
7-2
Reactors (STAR reformer and oxyreactor)
7-2
Recovery and purification of propylene
7-4
Compression
7-4
CO2 removal
7-4
Cold box
7-5
Fractionation
7-5
Refrigerant systems
7-6
Process discussion
7-6
Catalytic dehydrogenation
7-6
Catalyst regeneration
7-7
Recovery and purification of propylene
7-9
Process economics
7-18
Capital cost
7-18
Production cost
7-18
Profitability
7-19
Design conditions
B-1
Cost bases
B-1
Capital investment
B-1
Production costs
B-2
Effect of operating level on production costs
B-2
Feedstock and Energy Pricing
B-3
Appendix A: Patent summary table
A-1
Appendix B: Design and cost bases
B-1
Appendix C: Cited references
C-1
Appendix D: Patent references by company
D-1
Appendix E: Confidence ratings
E-1
Appendix F: Process flow diagrams
F-1
IHS CHEMICAL | Process Economics Program RP267A
October 2015
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© 2015 IHS
Table 2.1 World prices for propylene
2-5
Table 2.2: Summary economics of propane dehydrogenation process technologies
2-14
Table 3.1 Propylene grades for chemical manufacture
3-2
Table 3.2 World prices for propylene
3-10
Table 4.1 Process parameters for commercial PDH technologies
4-4
Table 4.2 UOP platinum dehydrogenation catalysts over time
4-8
Table 4.3 Chronology of representative forerunner patents for the STAR® catalyst technology
4-30
Table 5.1 Propylene from propane by the CATOFIN processDesign bases and assumption
5-7
Table 5.2 Propylene from propane by the CATOFIN processStream flows
5-8
Table 5.3 Propylene from propane by the CATOFIN processMajor equipment
5-9
Table 5.4 Propylene from propane by the CATOFIN processUtilities summary
5-10
Table 5.5 Propylene from propane by the CATOFIN processTotal capital investment
5-13
Table 5.6 Propylene from propane by the CATOFIN processCapital investment by section
5-14
Table 5.7 Propylene from propane by the CATOFIN processProduction costs
5-15
Table 6.1 Propylene from propane by the Oleflex processDesign bases and assumptions
6-6
Table 6.2 Performances of Oleflex dehydrogenation process
6-7
Table 6.3 UOP Oleflex catalyst development
6-8
Table 6.4 Propylene from propane by the Oleflex processStream flows
6-10
Table 6.5 Propylene from propane by the Oleflex processMajor equipment
6-11
Table 6.6 Propylene from propane by the Oleflex processUtilities summary
6-13
Table 6.7 Propylene from propane by the Oleflex processTotal capital investment
6-13
Table 6.8 Propylene from propane by the Oleflex processCapital investment by section
6-15
Table 6.9 Propylene from propane by the Oleflex processProduction costs
6-16
Table 7.1 Propylene from propane by the Uhde STAR processDesign bases and assumptions
7-10
Table 7.2 Propylene from propane by the Uhde STAR processStream flows
7-11
Table 7.3 Propylene from propane by the Uhde STAR processMajor equipment
7-12
Table 7.4 Propylene from propane by the Uhde STAR processUtilities summary
7-13
Table 7.5 Propylene from propane by the Uhde STAR processTotal capital investment
7-14
Table 7.6 Propylene from propane by the Uhde STAR processCapital investment by section
7-15
Table 7.7 Propylene from propane by the Uhde STAR processProduction costs
7-16
Table A.1 Patent summaries
A-1
Figure 3.1
China’s propylene self-sufficiency
3-4
Figure 4.1
Yields of various propylene production processes
4-2
Figure 4.2
Equilibrium conversion of light alkanes at 100 kPa pressure
4-3
Figure 4.3
Reactions catalyzed by platinum and acid sites during light paraffin
dehydrogenation with unmodified catalyst
4-6
Figure 4.4
Temperatures required to achieve 10% and 40% conversion of
C2–C15 paraffins at 1 atm
4-7
Figure 4.5
Conventional reactor configuration for propylene production in the Oleflex unit
4-10
Figure 4.6
Moving bed reactor with countercurrent and radial flow
4-11
Figure 4.7
Block flow diagram of conventional Oleflex process
4-14
Figure 4.8
Configuration diagram of the CATOFIN process for propylene production
4-23
Figure 4.9
Chemistry of the STAR process for propylene production
4-25
Tables
Figures
IHS CHEMICAL | Process Economics Program RP267A
October 2015
vi
© 2015 IHS
Figure 4.10
Effects of oxygen on conversion in the STAR process
4-26
Figure 4.11
Proposed mechanism of oxidative dehydrogenation on platinum
4-27
Figure 4.12
Catalyst preparation steps for Pt–Sn–Zn/Ca spinel PDH catalysts
4-32
Figure 4.13
Gas premixing assembly in DE 102004024957
4-35
Figure 4.14
STAR process oxyreactor assembly
4-36
Figure 4.15
Configuration diagram of the STAR process for propylene production
4-37
Figure 5.2
Reactor system
5-5
Figure 6.2
Catalyst regeneration
6-4
Figure 7.2
Both reaction trains in operation
7-8
Figure 7.3
One reaction train in regeneration
7-8
Figure 7.4
Carbon dioxide removal
7-9
Figure 5.1
Propylene from propane by the Lummus CATOFIN process
7-1
Figure 6.1
Propylene from propane by the UOP Oleflex process
7-2
Figure 7.1
Propylene from propane by the Uhde STAR process