On-purpose propylene production

Propane dehydrogenation plays an increasingly key role in closing the global

shortage in traditional propylene supplies

G
lobal demand for propyl-
ene continues to rise and Demand
the market is projected Other
Targeted
to enjoy solid growth rates for MTO
production
160 Propane
the foreseeable future. With this dehydrogenation
increase, however, traditional Growing
Refinery FCC Traditional propylene
Production, million tons

sources of propylene no longer Steam cracking production gap

meet demand. On-purpose
propylene solutions are neces-
sary to fill the propylene gap.
This article will overview the
market drivers for on-purpose
propylene production. It will
provide insight into the advan-
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tages of propane dehydrogena-
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tion (PDH) as the most efficient 27

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propylene production technol-

ogy in general, and Honeywell Figure 1 Global propylene production
UOP’s Oleflex process specifi-
cally as a high performing pro- goods ranging from kitchen ket demand for propylene and
cess technology. To demonstrate utensils and food containers to the ability of these traditional
the benefits of the technology, apparel, area rugs, and even sources to produce propylene
two examples are described. car batteries. Polypropylene is has been widening since 2011
a plastic that is widely consid- and is projected to continue
The propylene gap ered one of the most versatile, widening. On-purpose propyl-
Increasing opportunity exists and producers of propylene ene production technologies are
for profitable production of pro- as a byproduct have found no filling the gap (see Figure 1).
pylene. In 2018, 68% of the end- end to the demand for propyl- Propane dehydrogenation is
use demand for propylene was ene, driven by the demand for the primary on-purpose tech-
for polypropylene. Production polypropylene. nology in use, contributing 22%
of this plastic is increasingly Traditional sources of pro- of the propylene production that
important because the growing pylene as a by-product have is filling the supply/demand
middle class around the world, been steam cracking and fluid gap in 2018. By 2027, the per-
especially in developing nations, catalytic cracking (FCC). The centage is expected to grow to
needs more plastic for consumer growing gap between the mar- 32%. Other on-purpose propyl-

www.eptq.com PTQ Q1 2019 1

 ene technologies include meth- tors, followed by an independ-
anol to olefins (MTO), methanol + H2 ent regeneration section. The
to olefins plus olefin cracking Propane Propylene Hydrogen high yield, high activity plati-
(MTO + OC), and methanol to num-containing catalyst slowly
propylene (MTP). All of these Figure 2 PDH has the highest circulates through the reactors
options produce propylene propylene yield and enters the continuous cata-
yields that are at least double lyst regeneration (CCR) section,
those of the traditional technol- of a fractionation section and utilising UOP’s CCR technology
ogies. PDH has the highest pro- reaction section. The fractiona- and enabling steady-state cata-
pylene yield of all, at 85%. tion section consists of a depro- lyst regeneration (see Figure 3).
Propane dehydrogenation is paniser that purifies propane Key benefits of the process are
a simple process with one feed feed to the reaction section, a lower capital expenditure, lower
(propane) that is converted to deethaniser that removes lighter operating expenditure, better
one primary product (propyl- components from the reactor economy of scale, higher plant
ene) with the option to use the section product stream, a pro- productivity and dependability,
by-product (hydrogen) for fuel pane-propylene splitter, and a smaller environmental footprint,
or export for other uses (see small selective hydrogenation and UOP’s project execution,
Figure 2). A PDH unit is eas- reactor that removes diolefins technical services, and contin-
ily integrated at a propane from the propane, which is recy- uous innovation. Overall, the
source or at a downstream poly- cled to the depropaniser. financial benefits can add up
propylene production plant. The Oleflex reaction sec- to $20 million/y lower net cost
Honeywell UOP’s Oleflex pro- tion, which converts propane of production, an additional
cess is a leading PDH process to propylene and hydrogen, is $80 million of net present value
and will continue to hold that noteworthy for its steady-state and an additional 3% return on
place due to UOP’s investment operation design and small foot- investment compared to other
building on its expertise. print. These are achieved by PDH technologies.
using an independent reactor
The Oleflex process section consisting of four heater Lower capex
A complete Oleflex unit consists cells with four vertical reac- The streamlined design of
UOP’s PDH technology offers
several advantages for capital
Reaction Regeneration Product recovery expenditure. One of the main
section section section reasons the Oleflex process
requires significantly lower cap-
Catalyst ital expenditure is the highly
CCR flow
active and stable nature of the
platinum-containing Oleflex
catalyst. With high activity, a
smaller volume of catalyst is
required for the same design
Dryer
production. With high stabil-
ity, the unit can be designed
Reactor
effluent to tighter parameters because
Heater cells compressor catalyst deactivation is highly
predictable. Both of these fac-
To fractionation
section tors contribute to the smaller
Cold box size of Oleflex reactors when
compared to other PDH tech-
Fresh and Net gas nologies. Additionally, the pro-
recycle feed H2
cess is designed with positive
reactor pressures. This results
Figure 3 The Oleflex process in a smaller, simpler reactor

2 PTQ Q1 2019 www.eptq.com

effluent compressor as well as
1900−1995 1996−2000 2001−2005 2006−2010 2011−today
smaller piping and equipment
throughout the entire unit when DeH-6, 8 & 10
catalysts
DeH-12
catalyst
DeH-14
catalyst
DeH-16
catalyst
DeH-24 & 26
catalysts
compared to systems operat- 105−165kMTA 250−350kMTA 400−460kMTA 510 kMTA 750 & 1020 kMTA
ing under vacuum pressure. propylene propylene propylene propylene propylene design
designs design design design
Another key feature of the pro-
cess – the independent regen-
Mixed PDH/BDH UOP MD trays Fractionation New reactor Significant yield
commercialised for fractionation energy reduction internals improvements
eration section – comes with (UOP was first
Fired heater CCR Further energy
to market)
the inherent benefit to capital optimisation enhancements reduction

expenditure of avoiding expen- Reactor internals

enhancements
sive equipment such as large
isolation valves, large air blow-
Next generation
CCR
ers or drivers, a selective cata- Reliability Advisor is a
HPS automation
cloud-based process
lytic reduction system (SCR), or insights tool for prediction package

a wastewater stripping system.

and troubleshooting.
Reliability Advisor
All of these would be required
for a design that relies on cyclic Figure 4 Development of Oleflex technology
catalyst regeneration rather than
steady-state CCR technology. sors, and the absence of a steam Higher on-stream availability
Finally, Oleflex reactors are ori- purge. Oleflex technology has and productivity
ented vertically, resulting in a lower coke generation, which Higher on-stream availabil-
smaller plot plan that requires results in the benefits of reduced ity means higher productivity
only two-thirds of the footprint fuel or electric power require- and additional profit margin to
that other PDH units require. ment since no large air blowers the tune of up to $10-15 million
The advantages of UOP’s PDH are needed for catalyst regener- annually. This additional pro-
technology can result in a ation, and more light ends (C2-) ductivity also comes from the
15-20% saving in capex. by-product recovery for fuel or inherently simpler design of the
export. These opex advantages Oleflex process. Independent
Lower opex can add up to a $10/t propylene reactor and regenerator sec-
Similarly, its simplicity of design production saving for a 600 000 tions allow for online catalyst
and high performance make t/y propylene unit. changeout. There is no need to
Oleflex units simpler and less shut down the unit to change
expensive to operate. The sta- Better economy of scale the catalyst, so unit maintenance
bility of the catalyst results in As the propylene supply/ turnarounds can be planned
lower consumption of pro- demand gap continues to separately, allowing plant pro-
pane for the same propylene widen, companies are inter- ductivity to continue during
production over the catalyst ested in commissioning larger catalyst changeouts. The pro-
life. At 90%, the lion’s share and larger PDH units. Whether cess utilises adiabatic hot wall
of operating expenditure goes a unit is designed for 450 000 t/y reactors. These reactors do not
to the propane feed, so the or 750 000 t/y, the Oleflex pro- rely on internal reactor liners,
high product yield of Oleflex cess utilises four vertical reac- which can be susceptible to fail-
units compared to competing tors, incrementally sized for the ure, and thus avoid problems
PDH technologies gives opera- plant’s designed production. such as localised hot spots and
tors an advantage with operat- Competing PDH technologies, excessive coke generation, and
ing costs. Furthermore, utility with larger reactors, scale up by instead enjoy more stable opera-
costs are minimised due to the increasing by as many as dou- tion. The positive pressure reac-
lower compressor duty associ- ble the number of reactors. For tor design contributes to higher
ated with positive reactor pres- small or large applications, the plant reliability by avoiding the
sure, the absence of a need for Oleflex process maintains the need for hot isolation valves
nitrogen purge to seal valves, same configuration, offering that can be susceptible to fail-
the ability to regenerate with- the same benefits of a simple, ure. The process also achieves
out large utility air compres- streamlined design. reliability by avoiding concerns

www.eptq.com PTQ Q1 2019 3

 related to valve leaks that would fold, derived from the more cal services and multiple user
allow air into a system under advanced catalyst and lower training programmes are avail-
vacuum pressure. Finally, the process emissions. The highly able, including a plant opera-
independent reactor and regen- active platinum catalyst itself tion simulator. The Technology
eration sections do not require reduces environmental impact. Services department provides
cycling from widely different Compared to other catalysts, early and ongoing technical sup-
reaction to regeneration temper- as little as 25% of the volume port throughout the life of the
ature modes, allowing the sys- of high activity Oleflex cata- plant. The Process Reliability
tem to operate at steady state. lyst is required. This smaller Advisor is available as part of
Those familiar with the effects amount of material directly cor- the Honeywell Connected Plant
of thermal cycling will appre- responds to a smaller environ- cloud-based services. In addi-
ciate the significant advantage mental footprint. Additionally, tion, a users’ conference and
that steady state provides to reli- platinum does not require any hands-on workshops encourage
ability – less thermal stress, less special handling or disposal knowledge sharing and pres-
potential for equipment failure, compared with other PDH cat- entation of innovations as they
and more time on-stream. alysts, while the platinum is become available.
In addition to the reliability recoverable and recyclable. The Oleflex catalyst inno-
benefits inherent in the Oleflex design of the process allows it vations culminate in the
process, Honeywell UOP has to operate with significantly new DeH-26. UOP’s man-
the Process Reliability Advisor lower emissions. The signifi- ufacturing techniques are
(PRA) as part of Honeywell’s cantly lower coke formation employed in the production
Connected Plant to further opti- means there is significantly less of DeH-26 to create a custom-
mise plant productivity. This is combustion gas produced dur- designed catalyst support.
a cloud-based solution to moni- ing regeneration. In the Oleflex Platinum content is optimised
tor and optimise process perfor- process, this can result in five for high yields while maintain-
mance. It employs digital-twin times lower NOx, five times ing high activity, ramp-up to
plant models tuned to the cus- lower NH3, seven times lower full capacity is faster, and oper-
tomer’s operating conditions as greenhouse gases (such as CO2), ators will enjoy shorter start-up
well as fault models that analyse and eight times lower volatile times, longer run lengths and
cause and effect relationships. organic compounds (VOCs). increased hydraulic capacity.
Data directly from the plant is No steam is added in the pro- The key benefits of this new cat-
securely and smartly combined cess, eliminating a major source alyst were designed in direct
with process model information of wastewater; this can result in response to the needs of opera-
to give users guidance for max- 130 times less process wastewa- tors in the current market con-
imising efficiency and reliability, ter to be treated. Overall, Oleflex ditions. The first commercial
being proactive on key varia- units have a smaller impact on installation is expected to go
bles, and understanding poten- the health of people and the online in an existing Oleflex unit
tial issues. These would include environment. early in 2019.
why issues might be occurring, The latest process innova-
what is impacted, and what can Execution, services, and tions aim to extend on-stream
be done to rectify the situation. innovation time. Many operators today
UOP experts also monitor the A fast-to-market design are looking for a four-year run
PRA system remotely and pro- approach can enable startup length, mainly to allow for syn-
vide further valuable insights to in less than 36 months from chronising timing of planned
help customers run most reli- technology selection. A UOP- shutdowns with other units.
ably and profitably between supplied modular CCR is avail- Operating at significantly lower
planned shutdowns. able to simplify construction. temperatures reduces carbona-
During project execution, UOP ceous fouling which, in turn,
Smaller environmental experts draw on operational extends run length. UOP has
footprint experience from the 30 Oleflex achieved this by further optimis-
The environmental advantages units currently operating world- ing the conditions in the reactors
of the Oleflex process are two- wide. Comprehensive techni- to achieve the same conversions

4 PTQ Q1 2019 www.eptq.com

at lower temperatures with a than $5 million cost of produc- to be commissioned. UOP’s
lower hydrogen-hydrocarbon tion savings over the 2015-2018 Oleflex process is a leading on-
ratio. This way the key bene- period. Additionally, when purpose propylene production
fits of low opex and capex that the unit was designed in 2003, process, with more than 75% of
come with Oleflex technology the target run length between PDH projects and nearly 80% of
are maintained. A mechanical maintenance turnarounds was all propane or butane dehydro-
innovation providing increased 2-2.5 years. Like other opera- genation projects awarded to
open area for vapour flow with tors, this customer is interested UOP since 2011. Since 1990, nine
the newest reactor internals in extending cycle lengths. By operators have licensed multi-
increases the unit’s tolerance applying selected technology ple UOP Oleflex units, and nine
for fouling, further extending upgrades at the start of this customers have switched from
the time on-stream before a con- most recent cycle, the unit’s run a competitor’s dehydrogenation
straint is reached and a mainte- length reached three years. UOP unit to UOP Oleflex technology.
nance turnaround is required. and the operator are working
Enhanced sulphur injection, to incorporate further upgrades Michael Marsh is a Senior Product
optimised to synergise with targeting a four-year mainte- Marketing Manager for Olefins
the reactor temperature pro- nance cycle length. Technologies with UOP’s Process,
file improvements, reduces the Another operator experi- Technology & Equipment business.
His responsibilities include setting the
potential for iron sulphide foul- enced impressive results when
strategic direction and product roadmap
ing and further extends run implementing the Process
for the business and developing and
length. All of these process Reliability Advisor (PRA) from driving execution plans to deliver
design improvements are being the Honeywell Connected Plant. profitable outcomes. With previous
incorporated into currently This Middle Eastern petrochem- product marketing roles with UOP
operating Oleflex units and are ical complex with an Oleflex in petrochemical catalysts, aromatic
standard from 2018. unit strives to operate at peak derivatives technologies, and heat and
performance to improve profit- mass transfer process equipment, he
The technology in practice ability while meeting demand. holds a bachelor of science degree
An operator partnered with PRA enabled the operator, in in chemical engineering and a MBA
UOP to license and operate the first month, to increase pro- in finance from Rutgers, The State
University of New Jersey.
an Oleflex unit that started up cess efficiency at a rate of over
Jeffrey Wery is a Technology Manager
over 10 years ago. The unit was $1.2 million annually. Early
with UOP’s Process Technology &
designed for 350 000 t/y pro- event detection and resolution Equipment business, specialising in
duction and achieved 100% of with embedded root cause anal- olefins and detergents technologies
design. From start-up through ysis, the ability to operate closer and previously supported UOP-licensed
2015, the operator worked to constraints and improve pro- propane dehydrogenation units as a
closely with UOP to opti- cess performance by leverag- Technical Service Specialist with UOP’s
mise unit operations, selec- ing a digital twin of the process, Technical Services department. He holds
tively upgrading over the years and driving best operating prac- one US patent and a bachelor of chemical
with innovations that could be tices led to improved compres- engineering degree from the University
applied to their unit including sor efficiency, improved column of Minnesota – Twin Cities.
the catalyst regeneration sys- operations, and early warning of
tem, reactor internals and fired potential catalyst transfer issues. Amendment
heaters. During the most recent An author’s amendment to a graph was
catalyst cycle, from 2015 to the Review unable to be incorporated in the print
present, the unit routinely oper- The gap between propyl- edition of PTQ’s Q4 2018 issue. This arises in
ated at 107% of design produc- ene supply and demand has an article, Advanced catalyst characterisation
for higher hydrocracking performance, by
tion capacity while using 3% motivated on-purpose pro- Honeywell UOP authors (see Figure 5, page
lower fresh propane feed than pylene production since 42). Red lines in the graph are identified as
design. The unit has achieved 2011. As demand contin- representing HC-680 catalyst. They should
a higher propylene production ues to rise faster than sup- instead represent HC-620 catalyst. The
version of the graph as it appears in our
rate at a lower operating cost ply, more units designed to online edition is correct.
since start-up, resulting in more produce propylene continue

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