Professional Documents
Culture Documents
PO
A. Baria
Y. M. Gucor
G. G. Maraat
C. Torres
+
Propylene oxide - CH3CHCH2O
+
Total Global Propylene Oxide
Demand
3
3
+
Philippine Import of Propylene
Oxide
How is Propylene
Oxide currently
manufactured?
Chlorine
vs
Organic
Peroxide
+
Method
Chlorine Method
Description
Conversion of propylene to
chloropropanols.
Organic Peroxide
Method
Co-oxidation of Propylene
with organic chemicals in
the presence of catalyst.
Year developed
1960s
1970s
Advantage
Disadvantages
Sumitomo Chemical Co., Ltd. (2006). Development of New Propylene Oxide Process. R&D Report, SUMITOMO KAGAKU, vol. 2006-
Organic
Chemical
Byproduct
Disadvantage
Ethylbenzene
(For every 1T
PO) 2.5 T of
Styrene
monomer
Isobutane
(For every 1T PO)
2.1T Tert-butanol
Hydrogen
Peroxide
Water
Direct Synthesis
Description
Direct reaction of
H2 + O2 H2O2
Disadvantage
Advantage
Simplest method to
form hydrogen peroxide
Reduces capital
investment
and operating costs
How do we propose
to manufacture
Propylene Oxide?
+On-site H O strategy
2
Direct
10
synthesis of H2O2
HPP
Blanco-Brieva (2008). New Two-Step Process for Propene Oxide Production (HPPO) Based on the Direct Synthesis of Hydrogen Peroxide. Ind. Eng. Chem. Res. 2008,
+
The Plant
11
Blanco-Brieva (2008). New Two-Step Process for Propene Oxide Production (HPPO) Based on the Direct Synthesis of Hydrogen Peroxide. Ind. Eng. Chem. Res. 2008,
+
Reactor 1
H
2
12
+ O2 H 2O 2
Direct
Synthesis of H2O2
from H2 and O2
Trickle-bed
5%
reactor
Pd/C as catalyst
Raw Material
Price
(USD/k
g)
Consumption
Rate (kg/hr)
Source
Hydrogen (H2)
3.06
881
In situ
632,995
Atmospheric air
http://www.ika.rwth-aachen.de/r2h/index.php/Hydrogen_Pathway:_Cost_Analysis
+
Separator 1
13
+
Reactor 2
H2O2
14
Epoxidation
of propene
as catalyst
Raw Material
Price
(USD/kg
)
Consumption
Rate (kg/hr)
Source
Propene (C3H6)
1.44
18,396
Local
+
Separator 2
15
16
Plant
Capacit
y
Product
Price
Plant Location
Brgy. Lamao,
Limay, Bataan,
Central Luzon
17
+
The Process
18
Reactor
Unit
1
Direct
Synthesis
of
+
Hydrogen Peroxide in a TBR
Separation
Unit
1
Flash
Drum
+
Separation
Unit
2
Distillation
+
Columns
Reactor
Unit
1
Direct
Synthesis
of
+
Hydrogen Peroxide in a TBR
Main Reaction:
Reactor
Unit
1
Direct
Synthesis
of
+
Hydrogen Peroxide in a TBR
74.22% N2
21.16% O2
0.01% H2
1.53% Methanol
1.14% Water
1.95% H2O2
66%
Methanol
34% Water
Separation
Unit
1
Flash
Drum
+
0.01% H2
21.82% O2
76.54% N2
1.54% Methanol
0.09% Water
0.01% H2O2
1.17% Methanol
34.66% Water
64.17% H2O2
Main Reaction:
100%
C3 H 6
100%
C3 H 6
47.01% Propylene
Oxide
0.75% Methanol
37.26% H2O
13.87% H2O2
1.10% By-products
Separation
Unit
2
Distillation
+
Columns
47.01% Propylene
Oxide
0.75% Methanol
37.26% H2O
13.87% H2O2
1.10% By-products
100%
C3H6
Water
Methanol
Hydrogen Peroxide
66% Methanol
34% Water
Ethylene Glycol
Water
Methanol
Hydrogen Peroxide
Ethylene Glycol
Water
Hydrogen Peroxide
+
Cost Estimation
31
+
Equipment Cost
Reactor Unit 1
Separation Unit 1
Reactor Unit 2
Separation Unit 2
+
Equipment Cost
Reactor Unit 1
Separation Unit 1
Reactor Unit 2
Separation Unit 2
+
Reactor Unit 1
Equipment Description
Cost ($)
500,000.00
R-100
55,432.70
P-100
6,374.53
PM-100
12,845.38
V-100
15,838.32
E-101
62,698.87
Total
653,189.81
+
Equipment Cost
Reactor Unit 1
Separation Unit 1
Reactor Unit 2
Separation Unit 2
+
Separation Unit 1
Equipment Description
Cost ($)
T-100
Flash Vessel
1,089,388.90
20,336.20
E-202
Heat Exchanger
14,331.18
P-100A/B
Pump
5,643.75
PM-100A/B
Pump Motor
1,656.16
Total
1,131,356.20
+
Equipment Cost
Reactor Unit 1
Separation Unit 1
Reactor Unit 2
Separation Unit 2
+
Reactor Unit 2
Equipment Description
Cost ($)
P-200A/B
Pump
7,719.92
PM-200A/B
Pump Motor
3,311.23
E-200
Heat Exchanger
18,445.49
P-201A/B
1,325,139.27
PM-201A/B
52,007.04
E-201
89,159.28
R-200
CSTR
12,565.20
V-200
1,455,938.67
Total
2,964,286.09
+
Equipment Cost
Reactor Unit 1
Separation Unit 1
Reactor Unit 2
Separation Unit 2
+
Separation Unit 2
Equipmen
t
Description
Cost ($)
E-204
Heat Exchanger
20,870.00
E-206
Heat Exchanger
197,386.00
E-209
Heat Exchanger
12,284,798.00
E-203
Condenser
30,488.49
E-205
Condenser
323,148.94
E-208
Condenser
20,000,000
P-202A/B
Pump
899,150.69
P-202A/B
Pump Motor
41,238.69
T-200
Distillation Column
46,673.00
T-201
Distillation Column
30,042.00
T-202
Distillation Column
466,824.00
Total
32,250,102.30
+
Summary of Equipment Cost
Unit
Cost ($)
Reactor Unit 1
653,189.81
Separation Unit 1
1,131,356.20
Reactor Unit 2
2,964,286.09
Separation Unit 2
32,250,102.30
Total
36,998,934.39
+
Fixed Capital Investment: Direct
Cost
Percent
of
delivere
d
equipme
Minimu Maximu nt for
m
m
processi
Range Range ng plant
Cost
Final
Normali
ze
Direct Cost
Purchased equipment cost
Purchased equipment
installation
Instrumentation and
Control (installed)
Piping (installed)
Electrical systems
(installed)
Building (including services)
Yard improvements
Service facilities (installed)
15
40
40%
14
14%
36,998,934.3
9
12,949,627.0
4
2
3
8
20
8%
9%
7,399,786.88
8,324,760.24
5.26
5.92
10
10%
6.58
3
2
8
18
5
20
15%
2%
10%
9,249,733.60
13,874,600.4
0
1,849,946.72
9,249,733.60
26.32
9.21
9.87
1.32
6.58
+
Fixed Capital Investment: Indirect
Cost
Percent
of
delivere
d
equipme
Minimu Maximu nt for
m
m
processi
Range Range ng plant
Indirect cost
Engineering and
supervision
Construction expenses
21
13%
16
9%
Legal expenses
1%
Contractor's fee
4%
Contingency
15
15%
Cost
Final
Normalize
12,024,653.6 8.5526315
8
79
5.9210526
8,324,760.24
32
0.6578947
924,973.36
37
2.6315789
3,699,893.44
47
13,874,600.4 9.8684210
0
53
38,848,881
+
Total Fixed Capital Investment
Fixed Capital
Investment
Cost of H2 plant*
$ 140,595,950.69
Total Fixed
Capital
Investment
$
156,921,278.
78
$ 16,325,328.09
*Source: Mr. Koos Overwater of Technip Stone & Webster Process Technology
+
Working Capital
Annual
consumption
(kg/yr)
141550387.20
74464281.60
410.28
7140.91
Price
Material
(USD/kg)
Propylene
1.44
Methanol
0.49
TS-1 Catalyst
5600
5% Pd/C catalyst
666.4
41.9/1000
LP Steam Cost
kg
116501486.60
Cooling water 0.05/1000
cost
kg
31828325972.48
Demineralized 1.30/1000
water
kg
41891742.74
130/1000
Electricity
kWh
Total
254,695,629.
45
+
Annual Sales
Price
Annual
(USD/k production Revenue per
Material
g)
(kg/yr)
year ($)
1.58
167,991,715.7
Propylene
106,323,871
4
Oxide
+
Annual Sales
Price
Annual
(USD/k production Revenue per
Material
g)
(kg/yr)
year ($)
Propylene 1.58 106,323,871 167,991,715.74
Oxide
308,092,41
194,995,200
6.00
+
Cash Flow
200,000,000.00
$ 124,852,180.91
100,000,000.00
0.00
0
-100,000,000.00
-200,000,000.00
-300,000,000.00
-400,000,000.00
-500,000,000.00
$ -411,636,908.23
10
+
Profitability Analysis
49
+
IRR and NPV
IRR
NPV
26.73%
$ 394,566,100.49
+
Payback
500,000,000.00
400,000,000.00
300,000,000.00
200,000,000.00
100,000,000.00
0.00
0 5 10 15
-100,000,000.00
-200,000,000.00
-300,000,000.00
-400,000,000.00
-500,000,000.00
Investment Year
+
Conclusions and
Recommendations
52
53