OleflexTM Process for Propylene Production

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Introduction

The UOP Oleflex process is a catalytic dehydrogena-tion technology for the production of light olefinsfrom their corresponding paraffins. One specificapplication of this technology produces propylenefrom propane. Propylene is the word’s secondlargest petrochemical commodity and is used in theproduction of polypropylene, acrylonitrile, acrylicacid, acrolein, propylene oxide and glycols, plasticizeroxo alcohols, cumene, isopropyl alcohol, and acetone.The growth in propylene production is primarilydriven by the industry demand for polypropylene,which is used in such everyday products as packagingmaterials and outdoor clothing. The growth rate ofpolypropylene is expected to be 5% per year for thenear future. The Oleflex process provides:

� A dedicated source of propylene supply fordownstream use.

� Increased control over long-term propylene costs.� High-quality propylene production, which leads

to high-quality polymers.� Potential for process integration with downstream

technology.� Continuous on-stream production of propylene.

In addition, the Oleflex process utilizes UOP’s proprietary equipment and systems for optimaloperations, including PSA PolybedTM units, modularCCR, UOP lock hopper control, MDTM distillationtrays, High-FluxTM tubes, and process instrumenta-tion controls (PIC). Integration of these productswithin the Oleflex process results in significant capital and operating cost savings for the complexand provides an overall guarantee for the Oleflexprocess and products. With the use of CCR catalystregeneration, the processing unit does not have tobe shut down to change out the catalyst.

Applications

The majority of propylene is produced as a byproductof petroleum refineries (FCC/RCC) and olefin plantsteam crackers. As a result, most propylene is abyproduct of other products, specifically gasolineand ethylene. However, when production capacity is

not coupled with a demand for those byproducts, asupply/demand imbalance can occur. The Oleflexprocess provides petrochemical producers with acatalytic, on-purpose means of making propyleneindependent of the demand for gasoline and ethylene.

The Oleflex process provides producers with ahigh-quality propylene, which then leads to high-quality polymers.This processconsumes less polymerizationcatalystbecause offewer impuritiesin the propyleneproduct andhas the potentialto be integratedwith existingdownstreamtechnology.

Description

The UOPOleflex processis separated into three different sections: the reactorsection, the product recovery section, and the cata-lyst regeneration section.

The reactor section of the Oleflex process consists offour radial-flow reactors, charge and interstageheaters, and a reactor feed-effluent heat exchanger. In the product recovery section, the reactor effluentis cooled, compressed, dried, and sent to a cryogenicsystem to separate hydrogen from hydrocarbon. Thenet gas is recovered at 85 to 93 mol-% hydrogen purity. Separator liquid is sent to a selective hydro-genation unit to eliminate diolefins and acetylenes.Then the liquid goes to a deethanizer and propane-propylene (P-P) splitter to produce a chemical or polymer-grade propylene product. Unconvertedpropane is recycled to the reactor section.

The selective diolefin and acetylene hydrogenationstep is accomplished with the Hüls SHP process

Oleflex Process for Propylene Production 2

licensed by UOP. The catalyst regeneration sectionburns coke off the catalyst and returns it to freshactivity.

Feedstock

The feedstock to a C3 Oleflex process unit ispropane. Propane is recovered from propane-richLPG streams from gas plants. Propane is alsoavailable in smaller quantities as a byproduct fromsuch refinery operations as hydrocracking, fluidizedcatalytic cracking (FCC) and (RCC)* resid catalyticcracking units.

Catalyst

The Olexflex process uses a platinum catalyst topromote the dehydrogenation reaction. The DeH-14catalyst, introducted in 2001, represents the fifthgeneration of catalyst. Not only does the DeH-14maintain the high activity and selectivity and lowattrition rates required for the dehydrogenationprocess, it also has lower platinum investment thanearlier catalysts.

Commercial Experience

The Oleflex process was first commercialized in1990. Currently five propane units and one mixedpropane/isobutane unit produce more than 1,250,000MTA of propylene. In addition there are five isobu-tane units that have been commissioned.

For more information

For more information, contact your local UOP representative or our Des Plaines sales office:

e-mail: info@uop.comfax: +1-847-391-2253phone: +1-847-391-2000

Oleflex SHP

PropaneFeed

Net Gas H2

C2-

Propylene

C4+

Depropanizer

De-ethanizer

P-P Splitter

Reactor Section CCR Section

Heaters

Fresh andRecycle Feed

Net SeparatorOffgas

To PropyleneRecovery

TurboExpander

Rx EffluentCompressor

Dryer

H2 Recycle

CCR

Product Separation Section

C3

Oleflex Process

C3

Oleflex Complex

© 2007 UOP LLC. All rights reserved.The information in this document should not be construed as a representation for which UOP assumes legal responsibility, or an authorization or recommendation to practice a patented invention without a license.UOP 4522-2 0407OD0B

UOP LLC25 East Algonquin RoadDes Plaines, IL 60017-5017 U.S.A.www.uop.com