The Production of Propylene Oxide Using Cell Liquor Meshal Al-Rumaidhi Hassan Ghanim Ali Al-Haddad Abdulrahman Habib Supervised by: Prof. : Mohammed Fahim Eng. : Yousif Ali

Agenda Introduction Production Routes Reactions Feed Stocks (Raw Material) Final Product Thermodynamics Yield Calculation Process Technology and Flowsheets Process Alternatives (Licensors) Health and Safety Issues Uses of Propylene Oxide World Production Comparison of PO Production Routes Conclusion

Introduction What is Propylene Oxide? Propylene oxide (also known as PO, methyloxirane, 1.2-epoxypropane) is a significant organic chemical used primary as a reaction intermediate for production of polyether polyols, propylene glycol, alkanolamines (qv), glycol ethers, and many other useful products. It is an important propylene-derived chemical. In the united state, it is estimated that PO is the third largest derivative of propylene.

Cont. Introduction History of Propylene Oxide: The first preparation of PO was reported in wurz’s laboratory in 1860 union carbide started development in 1925, and PO became a leading industrial chemical after World War II when its importance in polyurethanes was recognized.

Production Routes The selection of production routes is decisively influenced by the application and market potential of co-products, as well as by availability of raw materials and possibilities for byproduct management. Technologies developed up to this point can be divided into: Chlorohydrin Processes Indirect Oxidation Processes Direct Oxidation Processes

Cont. Production Routes

Reaction Chlorohydrin Reaction: Saponification Reaction:

Feed Stocks (Raw Materials) Propylene Chlorine Water Sodium Hydroxide

Final Product Physical and Chemical properties for Propylene Oxide (PO): Propylene oxide is a colorless, highly volatile, very soluble in water, and flammable liquid at room temperature and normal atmospheric pressure. Physical State Liquid Odor Ethereal Molecular Weight 58.08 g/mol Boiling Point 34.23 °C Melting Point -111.93 °C Flash Point -37 °C

Thermodynamics The PO production is consisting of three exothermic reactions: Chlorohydrin Reaction Saponification Reaction

Yield Calculation Conversion of Propylene = 97% Selectivity of propylene = 95% Yield = Selectivity * Conversion = 0.97*0.95 = 92.15% Real yield PO = 89.4% The calculation yield is approximate to real yield.

Process Technology and Flowsheets Design Bases & Assumption Chlorohydrination Type of reactor Packed column Temperature & Pressure 40 °C & 60 psia Conversion of Propylene 97% Selectivity to PCH 95 mol% Selectivity to PDC 3.7 mol% Selectivity to DCIPE and other 1.3 mol% Saponification Type of reactor Tray column Temperature & Pressure 85 °C & 65 psia Amount of cell liquor added 1% excess alkali Conversion of PCH 99.9% Selectivity to PO 95 mol% Selectivity to propylene glycol 5 mol%

Process Conditions Chlorohydrination: Type of reactor Packed Columns Temperature 40 oC Pressure 60 psia Saponification: Type of reactor Tray Column Temperature 85 oC Pressure 65 psia

Health and Safety Issues Flammability Hazards Reactivity Hazards Explosibility Toxicology and Occupational Health Hazards

Uses of Propylene Oxide PO is an important basic chemical intermediate. Virtually all the PO produced is converted into derivatives, often for applications similar to those of ethylene oxide (EO) derivatives. PO is used primarily to produce polyether polyols, propylene glycols, propylene glycol ethers and, and many other useful products.

Cont. Uses

Cont. Uses

World Production

Process Alternatives (Licensors) PO Using Chlorohydrine Process by Lime. PO Using Indirect Oxidation Process by Isobutane. PO Using Indirect Oxidation Process by Ethyl Benzene. PO by Direct Oxidation.

Reaction (Chlorohydrine Process by Lime) Chlorohydrin Reaction: Saponification Reaction:

Process Conditions Chlorohydrination: Type of reactor Packed Columns Temperature 49 oC Pressure 17 psia Saponification: Type of reactor Tray Column Temperature 92 oC Pressure 22 psia

Typical arrangement for PO using chlorohydrins process by Lime Propylene chlorohydrin reactor; b) Separator; c) Vent gas scrubber; d) Saponifier; e) Partial condenser; f) Cross exchanger; g) Compressor; h) Propylene oxide purification train; i)Drums

Reaction (Indirect Oxidation Process by Isobutane) The main reaction of this process

Process Conditions (Indirect Oxidation Process by Isobutane) Type of reactor Peroxidation reactor Temperature 120 – 140 oC Pressure 25 – 35 bar Catalyst not needed Type of reactor Epoxidation reactor Temperature 110 oC Pressure 40 bar Catalyst Molybdnum

Flow scheme for PO-tert butyl alcohol a) Vent column; b) Lights scrubber; c) PO column; d) tert-butyl alcohol lights column; e) tert-butyl alcohol column

Reaction (Indirect Oxidation Process by Ethyl Benzene) The main reaction of this process

Process Conditions (Indirect Oxidation Process by Ethyl Benzene) Type of reactor Peroxidation reactor Temperature 146 oC Pressure 2 bar Type of reactor Epoxidation reactor Temperature 100 oC Pressure 35 bar Catalyst Molybdnum Type of reactor Dehydration reactor Temperature 270 oC Pressure 0.35 bar Catalyst Alumina

Flow scheme for PO-styrene process a) Separator; b) Recycle column; c) Crude PO column; d) Ethylbenzene recycle column

PO by Direct Oxidation The Disadvantage of Direct Oxidation: Difficult in Controlling Temperature. Several of by-Products.

Comparison of PO Production Routes: Chlorohydrin process, % 58 55 49 PO/styrene process, % 18 19 24 PO/tert-butyl alcohol process, % 24 26 24 Direct oxidation, % 0 0 2 World PO capacity, 1000 t/a 3300 3900 4900 World PO consumption, 1000t/a 2600 3250 3900

Conclusion Propylene oxide via Chlorohydrin Processes Using Cell Liquor is useful technique and has many advantages that our country needed. We cannot decide if it’s the best method before we studying the costs.

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