(161b) Comparative Process Analysis Techniques Applied to Four Propylene Oxide Manufacturing Routes

Comparative
Process Analysis Techniques Applied to Four Propylene Oxide Manufacturing
Routes

Dr.
John C. Prindle, Jr., P.E.

Torchwood Enterprises, LLC

Several chemistries are
being practiced commercially to manufacture propylene oxide.  These include the
conventional routes via t-butyl hydroperoxide, ethylbenzene hydroperoxide (Shell’s
SMPO process), hydrogen peroxide (BASF/DOW), and the proposed direct propylene epoxidation
using hydrogen/oxygen mixtures.  The challenges of staying competitive in this
market require an understanding of the advantages/disadvantages for both your and
your competitors’ processes. 

Comparative analysis of
the commercial-scale processes using an available simulation package is one way
of gaining this understanding.  This task, however, contains major obstacles.  Reaction
kinetic models have been reported for many of the reactions practiced and proposed. 
However, many are heterogeneous multi-site models and cannot be directly entered
into any of the simulation packages.   Even though a statistical range is
typically reported for each kinetic parameter in these models, how will the acceptable
variation in these parameters impact downstream separations?  Are there better
separation alternatives which might be less sensitive to these parameter
variations? This presentation will discuss the advantages and challenges of
applying ASPEN Plus® to the simulation of a commercial-scale process for each
of the four routes.  Several findings from this comparative analysis will be highlighted.