Manufacturing of Propylene Oxide. Investment Opportunities in Chemical Industry.
Propylene oxide is an organic compound with the molecular formula CH3CHCH2O. This colorless volatile liquid with an odor resembling ether, is produced on a large scale industrially. Its major application is its use for the production of polyether polyols for use in making polyurethane plastics.
Propylene oxide liquid and vapor are extremely flammable. Vapors may travel long distances and are heavier than air. Vapor may cause flash fire or explosion. Aqueous mixtures with propylene oxide concentrations as low as 0.75% may be flammable.
Propylene oxide is used in agriculture as an insecticidal fumigant and sterilant, to control bacteria contamination, moulds contamination, insect infestations, and microbial spoilage of food products as well as to control insects in non-food products. Propylene oxide is also a commercially important industrial chemical finding application as an intermediate for a wide array of products.
Propylene Oxide is a synthetic, highly-flammable, volatile, colorless liquid that is soluble in water and miscible with many organic solvents. Propylene oxide is used primarily as a chemical intermediate in the production of polyether’s and propylene glycol. It is also used as a pesticide and a fumigant for the sterilization of packaged foods and plastic medical instruments. Acute inhalation exposure to vapors of this compound can result in respiratory tract irritation, coughing, difficulty in breathing (dyspnea) and buildup of fluid in the lungs (pulmonary edema) that can possibly lead to pneumonia. Inhale high concentrations of the vapors for short time periods may cause headache, motor weakness,
The purpose of this bulletin is to disseminate recent information on the potential carcinogenicity of propylene oxide. The chronic effects of this chemical in animals have produced evidence that cancer is associated with exposure to propylene oxide. This bulletin describes of those animal, presents the known human health effects of propylene oxide, and suggests guidelines for minimizing occupational exposures. Propylene oxide at room temperature is a volatile, colorless, highly flammable liquid with a sweet, ether-like odor. The odor threshold for propylene oxide vapor is reported to be 200 parts of propylene oxide per million parts of air (200 ppm) in humans.
Uses
- Polyols used for the polyurethane foam (PUF) for the coatings, adhesives and sealants furniture, refrigerator, automotive industries,
- Propylene glycol ethers for the use as solvents in resins, cleaners, waxes paints, inks, and coatings
- Propylene glycols, even for the production of unsaturated polyester resins transportation, automotive, marine industries, and, construction
- Propylene glycols used as solvents in cosmetics, pharmaceuticals, food
- Propylene glycols is also used in aircraft de-icers and engine coolants
- Butanediol and its related products used for resins and solvents.
- Most propylene oxide is used as an intermediate in the production of polyether polyols for polyurethane foams, and in the production of propylene glycol for unsaturated polyester resins.
- Minor quantities are used for sterilizing medical equipment and for fumigating foodstuffs
- The major use of propylene oxide is in the production of polyether’s (the primary component of polyurethane foams) and propylene glycol.
- Propylene oxide is also used in the fumigation of foodstuffs and plastic medical instruments and in the manufacture of propylene glycol and glycol ethers, as herbicides, as solvents, and in the preparation of lubricants, surfactants, and oil demulsifies
Process
Propylene oxide is traditionally made by chlorohydrin and epoxidation routes, but newer technologies based on hydrogen peroxide or cumene hydro peroxide have been commercialized. A significant amount of propylene oxide capacity is still based on the older chlorohydrin process.
The plants using this route are often integrated with chlor-akali plants which consume a large amount of power in making chlorine and caustic soda. Consequently, extensive effluent treatment is needed to handle the waste stream. Another process that had once gained in popularity was the propylene oxide /styrene monomer (propylene oxide /SM) route. The disadvantage here, though, is the potential coproduction of 2.25 tonnes of styrene for every tonne of propylene oxide, which can present difficulties in balancing the markets for propylene oxide and styrene. This can lead to volatility over time in performing the operations economically. Capital costs can also be relatively high in the propylene oxide /SM route. A number of propylene oxide /SM plants have been built by companies such as Spain’s Repsol, Ellba (Shell/BASF) and Netherlands-based LyondellBasell.
New propylene oxide technologies without co-products have now been developed and commercialized, including a cumene hydro peroxidation technology. In addition, a number of companies have developed technologies to make propylene oxide from propylene and hydrogen peroxide a process known as HPPO.
Market Outlook
Global propylene oxide market is expected to show significant growth of increasing polyurethanes’ demand in various segments including packaging, automotive, footwear, furniture, and construction. Rising use of polyurethanes in sealants, thermal insulators, and flooring materials will drive industry growth over the next seven years. Rising infrastructure spending in China, Malaysia, Singapore, Brazil, India, UAE, Saudi Arabia, and Qatar is expected to drive demand over the forecast period. In addition, growing automotive sector in various countries including in China, Mexico, the U.S., and India is expected to increase market.
Propylene glycol is widely deployed as a construction chemical for use in paints, grouts, adhesives, waterproofing materials, and coatings, in both infrastructure and the construction industry. A wide-ranging number of propylene glycol applications are anticipated to be an important driver of the propylene oxide market in the days ahead. Another industry that is witnessing a resurgence in recent times is the automotive industry. This should directly benefit the propylene oxide market as the products are utilized in a number of components such as flexible foams, paints, adhesives, and sealants. Thus, it can be said that the propylene oxide market is intrinsically linked to the automotive industry.
Propylene is used to produce flexible foams for bedding, furniture, carpet underlay, bedding and seat cushioning in automotive while polyurethanes are used to produce rigid foams for thermal insulation in packaging & commercial refrigeration and construction industry. Toxic nature of propylene oxide, development of alternatives of oxide, negative effects of the product in the environment, and the high price of raw materials will hinder the growth of the market.
Propylene oxide finds its application in tub-shower, gasoline tanks, and boat hulls. Rise in the consumption of products that include polyalkylene glycols, propylene glycols, and propylene glycol ethers will propel market expansion. High consumption in lubricants, defoamers, greases, oil-field chemicals, latex paints, wetting agents, and water scavengers will increase the revenue generated by the market.
Europe was the largest in terms of Propylene Oxide consumption. However, it is anticipated that it would lose it market share due to the economic crisis and increasing environmental regulations and safety.
The propylene oxide market is expected to grow at a CAGR of around 5.9% during of 2019-2024. The increasing infrastructure spending in emerging economies, like China, India, and Brazil is likely to provide opportunities. The increasing use of propylene derivative, polyurethane, in the construction industry, has widely helped the propylene oxide market to have a strong hold in the construction and infrastructure segments.
Global Propylene Oxide Market, 2015-2023 (USD Million)
Propylene oxide (CH3CHCH2O) is a colorless volatile liquid. It is an organic compound used in the production of polyether polyols, which in turn is used in the production of polyurethane plastics. Propylene oxide can be produced by hydrochorination or oxidation. Propylene oxide has various applications in automotive and construction industries. Flexible foams, paints, sealants, coolants, car seats brakes, and hydraulic fuels are components which propylene oxide in the automotive industry Also, it is used as a chemical for paints, waterproofing, coatings, adhesives, grouts, and materials. However, availability of substitutes for propylene oxide are restraining growth of the market.
In the Middle East & Africa region, growing hotel construction, and public infrastructure have been driving the construction industry in the region. Besides, the residential construction is also strong in North America, due to high housing demand due to growing population demand for homes, and trend of nuclear families, which is further projected to drive the demand for propylene oxide market. Whereas, Europe has been witnessing healthy recovery of construction activities, which is expected to further increase the demand for propylene oxide in the years to come. Hence, all such trends in the global construction industry are expected to positively influence the demand for propylene oxide.
Propylene oxide (PO) is a key intermediate in the chemical industry. For instance, PO is mainly used to produce polyether polyols (65%), as well as propene glycol (30%) and propene glycol ethers (4%) (The second and third largest applications, respectively) which are mainly applied to manufacture commercial products such as adhesives, solvents, and foams. The annual worldwide production of PO amounted to 8.06 million tons and will likely go beyond 9.56 million tons and this market is annually growing.
Northeast Asia is forecast to remain the major source of new propylene oxide requirements. The Indian Subcontinent will benefit from an even faster demand growth rate, albeit from a much smaller base. Northeast Asia will continue to add capacity at a sustained rate: North America, Southeast Asia, the Indian Subcontinent and Western Europe are also expected to increase their capacity base, but to a much lesser extent. Overall, capacity additions are projected to be greater than consumption growth.
Despite some environmental concerns in some countries (the United States, Canada, Japan), MTBE has continued to be an attractive gasoline blend stock as the global demand for octane has increased because of the growth of smaller engines and the low complexity of Chinese refineries. Nevertheless, a recent change in Chinese gasoline policy is expected to alter the MTBE market in the medium term; the country is now aiming to develop an E-10 gasoline, comprising 10% ethanol—thus requiring less MTBE. The number of new PO/TBA plants is therefore expected to gradually slow down over the next five years.
There are three main routes to commercial production of propylene oxide—chlorohydrin, peroxidation (PO/SM, PO/TBA), and hydro peroxidation (HPPO and HPCU) processes. While the recent hydro peroxidation processes have gained significant momentum over the past decade, the traditional routes (chlorohydrin, peroxidation) still dominate globally. The majority of new PO production units are now designed to minimize or even avoid coproduct generation, as the marketing of coproducts has presented its own set of challenges for producers. More specifically, styrene markets had been in oversupply for quite some time, leading to limited investment into new PO/SM facilities; PO/SM investments are nevertheless now resuming as the styrene market has recovered following a decade of industry restructuring and asset rationalization.
Propylene oxide belongs to the epoxide family of products, and is used principally in the manufacture of polyether polyols, propylene glycols, glycol ethers, and polyalkylene glycols. Overall, propylene oxide consumption is broadly tied to the general economy and has been increasingly linked to emerging countries (China, in particular), where improvements in living standards are driving an increasing use of a wide range of polymers and chemicals.
Propylene oxide capacity has increased at an average rate of 3% per year, driven mainly by new developments in Asia. Meanwhile, Propylene oxide consumption has grown at a stronger pace (4.2% per year on average) leading to a tightening of markets and rising average operating rates across the propylene oxide industry. The industry-wide utilization rate was estimated at 93%, up from the 88% recorded five years ago.
Key Players
- BASF,
- The Dow Chemical,
- Huntsman International,
- Royal Dutch Shell,
- INEOS, Balchem,
- SKC,
- Sumitomo Chemical,
- Repsol,
- LyondellBasell Industries,
- SABIC,
- Tokuyama
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