FILLING THE PROPYLENE GAP – SHAPING THE

FUTURE WITH ON-PURPOSE TECHNOLOGIES

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Introduction
Global demand for propylene continues to rise and the market
Authors
is projected to enjoy solid growth rates for the foreseeable
future. With this increase, however, traditional sources of
propylene no longer meet the demand. On-purpose propylene
solutions are necessary to fill the propylene gap. This paper
will overview the market drivers for on-purpose propylene
production. It will provide insight into the advantages of
propane dehydrogenation (PDH) as the most efficient
propylene production technology in general, and Honeywell
UOP’s Oleflex™ process specifically as the highest performing
Michael Marsh
process technology available. To demonstrate how the
benefits of UOP technology play out in practice, two examples
are briefly described.

Jeff Wery
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Table of contents
3 The Propylene Gap

4 The Oleflex Process Described

5 Lower Capex

5 Lower Opex

5 Better Economy of Scale

6 Higher On-Stream Availability and Productivity

6 Smaller Environmental Footprint

7 Superior Execution, Services, and Innovation

8 Leading Technology in Practice

9 Review
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The Propylene Gap

Increasing opportunity exists for profitable production of propylene. In 2018, 68% of the end-use
demand for propylene was for polypropylene. Production of this plastic is increasingly important
because the growing middle class around the world, especially in developing nations, needs more
plastic for consumer goods ranging from kitchen utensils and food containers to apparel, area rugs,
and even car batteries. Polypropylene is a plastic that is widely considered one of the most versatile
and producers of propylene as a by-product have found no end to the demand for propylene, driven
by the demand for polypropylene.

Traditional sources of propylene as a by-product have been steam cracking and fluid catalytic
cracking (FCC). The growing gap between the market demand for propylene and the ability of
these traditional sources to produce propylene has been widening since 2011 and is projected
to continue widening. On-purpose propylene production technologies are filling the gap.

Global Propylene Production

Global Propylene Production
160
“Growing Propylene Gap”
On
Purpose
Million Tons

Traditional
Supply

2003 2005 2007 2009 2011 2013 2015 2017 2019 2021 2023 2025 2027

Steam Cracking Refinery FCC Propane Dehydrogenation

MTO Other On-Purpose Demand
Data source: IHS

Propane dehydrogenation is the primary on-purpose technology in use, contributing 22% of the
propylene production that is filling the supply/demand gap in 2018. By 2027, the percentage is
expected to grow to 32%. Other on-purpose propylene technologies include methanol to olefins
(MTO), methanol to olefins plus olefin cracking (MTO + OC), and methanol to propylene (MTP). All of
these options produce propylene yields that are at least double those of the traditional technologies.
PDH has the highest propylene yield of all, at 85%.

PDH Has The Highest Propylene Yield

+ H2
Propane Propylene Hydrogen
Propane dehydrogenation is a simple process with one feed (propane) that is converted to one primary
product (propylene) with the option to use the by-product (hydrogen) for fuel or export for other uses.
A PDH unit is easily integrated at a propane source or at a downstream polypropylene production plant.
Honeywell UOP’s Oleflex process is a leading PDH process on the market and will continue to hold that
place due to UOP’s ongoing investment building on the most outstanding expertise in the industry.
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The Oleflex Process Described

A complete Oleflex unit consists of a fractionation section and reaction section. The fractionation
section consists of a depropanizer that purifies propane feed to the reaction section, a deethanizer
that removes lighter components from the reactor section product stream, a propane-propylene
splitter, and a small selective hydrogenation reactor that removes diolefins from the propane, which
is recycled to the depropanizer.

The Oleflex reaction section, which converts propane to propylene and hydrogen, is noteworthy for
its steady-state operation design and small footprint. These are achieved by using an independent
reactor section consisting of four heater cells with four vertical reactors, followed by an independent
regeneration section. The high yield, high activity platinum-containing catalyst slowly circulates
through the reactors and enters the continuous catalyst regeneration (CCR) section, utilizing
UOP’s well established CCR technology and enabling steady-state catalyst regeneration.

The Oleflex Process

Reactor Regeneration
Section Section

Catalyst Flow
CCR

Dryer
Rx Effluent
Compressor
Heater Cells

Cold Box
Fractionation
Section
H2 Recycle
Fresh Net Gas (H2)
& Recycle
Feed Product Recovery Section

Key benefits of the Oleflex process are lower capital expenditure (capex), lower operating expenditure
(opex), better economy of scale, higher plant productivity and dependability, smaller environmental
footprint, and UOP’s premier project execution, technical services, and continuous innovation.
Overall, the financial benefits can add up to $20 million/year lower net cost of production and an
additional $80 million of NPV (net present value) and an additional 3% ROI (return on investment)
compared to other PDH technologies.
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Lower Capex
The streamlined design of UOP’s PDH technology offers several advantages for capital expenditure.
One of the main reasons the Oleflex process requires significantly lower capital expenditure is the
highly active and stable nature of the platinum-containing Oleflex catalyst. With high activity, a
smaller volume of catalyst is required for the same design production. With high stability, the unit can
be designed to tighter parameters because catalyst deactivation is extremely predictable. Both of
these factors contribute to the smaller size of Oleflex reactors when compared to other PDH
technologies. Additionally, the Oleflex process is designed with positive reactor pressures. This
results in a smaller, simpler reactor effluent compressor as well as smaller piping and equipment
throughout the entire unit when compared to systems operating under vacuum pressure. Another key
feature of the Oleflex process – the independent regeneration section – comes with the inherent
benefit to capital expenditure of avoiding expensive equipment such as large isolation valves, large
air blowers or drivers, a selective catalytic reduction system (SCR), or a waste water stripping system.
All of these would be required for a design that relies on cyclic catalyst regeneration rather than
steady-state CCR technology. Finally, Oleflex reactors are oriented vertically, resulting in a smaller
plot plan that requires only 2/3 of the square footage that other PDH units require. The advantages
of UOP’s PDH technology can result in a 15% to 20% savings in capex.

Lower Opex
Similarly, the simplicity of design and high performance make Oleflex units simpler and less
expensive to operate. The stability of the catalyst results in lower consumption of propane for the
same propylene production over the catalyst life. At 90% of opex, the lion’s share of operating
expense goes to the propane feed, so the high product yield of Oleflex units compared to competing
PDH technologies gives operators a big advantage with operating expenses. Furthermore, utility
costs are minimized due to the lower compressor duty associated with positive reactor pressure, the
absence of a need for nitrogen purge to seal valves, the ability to regenerate without large utility air
compressors, and the absence of a steam purge. Oleflex technology boasts lower coke generation,
which results in the benefits of reduced fuel or electric power requirement since no large air blowers
are needed for catalyst regeneration, and more light ends (C2-) by-product recovery for fuel or export.
These opex advantages can add up to a $10/MT (metric tons) propylene production savings for a
600 kMTA (thousand metric tons per annum) propylene unit.

Better Economy of Scale

As the propylene supply/demand gap continues to widen, companies are interested in commissioning
larger and larger PDH units. Whether a unit is designed for 450 kMTA, or 750 kMTA, the Oleflex
process utilizes four vertical reactors, incrementally sized for the plant’s designed production.
Competing PDH technologies, with larger reactors, scale up by increasing to as many as double the
number of reactors. For small or large applications, UOP’s Oleflex process maintains the same
configuration, offering the same benefits of a simple, streamlined design.
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Higher On-Stream Availability

and Productivity
Higher on-stream availability means higher productivity and additional profit margin to the tune of
up to $10-15 million annually. This additional productivity also comes from the inherently simpler
design of the Oleflex process. Independent reactor and regenerator sections allow for online catalyst
changeout. There is no need to shut down the unit to change the catalyst, so unit maintenance
turnarounds can be planned separately allowing plant productivity to continue during catalyst
changeouts. The process utilizes adiabatic hot wall reactors. These reactors do not rely on internal
reactor liners, which can be susceptible to failure, and thus avoid problems such as localized hot
spots and excessive coke generation, and instead enjoy more stable operation. The positive pressure
reactor design contributes to higher plant reliability by avoiding the need for hot isolation valves that
can be susceptible to failure. Oleflex also achieves reliability by avoiding concerns related to valve
leaks that would allow air into a system under vacuum pressure. Finally, the independent reactor
and regeneration sections do not require cycling from widely different reaction to regeneration
temperature modes, allowing the entire system to operate at steady state. Readers familiar with the
effects of thermal cycling will comprehend the significant advantage that steady state provides to
reliability—less thermal stress, less potential for equipment failure, and more time on-stream.

In addition to the reliability benefits inherent in the Oleflex process, Honeywell UOP offers the Process
Reliability Advisor (PRA) as part of Honeywell’s Connected Plant to further optimize plant productivity.
This is a cloud-based solution to monitor and optimize process performance. It employs digital-twin
plant models tuned to the customer’s operating conditions as well as fault models that analyze cause
and effect relationships. Data directly from the plant is securely and smartly combined with process
model information to give users guidance for maximizing efficiency and reliability, being proactive on
key variables, and understanding potential issues. These would include why issues might be occurring,
what is impacted, and what can be done to rectify the situation. UOP experts also monitor the PRA
system remotely and provide further valuable insights to help customers run most reliably and
profitably between planned shutdowns.

Smaller Environmental Footprint

The environmental advantages of the Oleflex process are twofold, derived from the more advanced
catalyst and lower process emissions. The highly active platinum catalyst itself reduces environmental
impact. Compared to competing catalysts, as little as 25% of the volume of high activity Oleflex
catalyst is required. This smaller amount of material directly corresponds to a smaller environmental
footprint. Additionally, platinum does not require any special handling or disposal compared with other
PDH catalysts, while the platinum is recoverable and recyclable. The unique design of the Oleflex
process allows it to operate with significantly lower emissions. The significantly lower coke formation
means there is significantly less combustion gas produced during regeneration. In the Oleflex
process, this can result in five times lower NOx, five times lower NH3, seven times lower greenhouse
gasses (such as CO2), and eight times lower volatile organic compounds (VOCs). No steam is added
into the Oleflex process, eliminating a major source of waste water and can result in 130 times lower
process waste water to be treated. Overall, Oleflex units have a smaller impact on the health of people
and the environment, which is an important consideration when selecting a technology.
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Superior Execution, Services, and Innovation

UOP’s hallmarks include complete customer satisfaction and long-term technology partnerships in
all areas of business, including their Oleflex units. UOP provides superior project execution with a
world-class engineering design and commissioning experience. A fast-to-market design approach
can enable startup in less than 36 months from technology selection. A UOP-supplied modular CCR
is available to simplify construction. Throughout project execution, UOP experts draw on the
industry’s largest pool of operational experience coming from the 30 Oleflex units currently
operating worldwide. UOP offers comprehensive technical services, and multiple user training
programs are available, including a plant operation simulator. The Technology Services department
provides early and ongoing technical support throughout the life of the plant. The Process Reliability
Advisor is available as part of the Honeywell Connected Plant cloud-based services. In addition, UOP
and Oleflex operators come together regularly at a UOP-hosted Users Conference and at hands-on
workshops that encourage knowledge sharing and allow UOP to present new innovations as they
become available.

UOP is committed to continuous technology innovation in all of its processes, including Oleflex.
The record of continuous innovation for Oleflex technology spans from the initial PDH units of the
early 1990s to present day, with more in development. UOP’s track record of investing in catalyst
innovations, increasing design capacity, operational efficiencies, and more innovations over the
years, provides operators with a highly advanced and refined PDH technology.

Oleflex Technology
Oleflex Technology – A Record
– A Record of Continuous of Continuous Innovation
Innovation

1990-1995 1996-2000 2001-2005 2006-2010 2011-to date

• DeH-6, 8 & 10 • DeH-12 catalyst • DeH-14 catalyst • DeH-16 catalyst • DeH-24 & 26 catalysts
catalysts
• 750 & 1020 kMTA
• 250 - 350 kMTA • 400 - 460 kMTA • 510 kMTA design
• 105 - 165 kMTA design design design
Key Advancements

propylene designs • Significant Yield

• UOP MD Trays for • Fractionation • New Rx Internals Improvements
• Mixed PDH/BDH Fractionation Energy Reduction
Commercialized • Further Energy Reduction
(UOP 1st to Market)
• CCR
• Fired Heater Enhancements • Rx Internals Enhancements
Optimization
• Next Generation CCR

• HPS Automation Package

• Reliability Advisor, cloud-

based process insights tool for
prediction & troubleshooting

The latest Oleflex catalyst innovations culminate in the newly available DeH-26. UOP’s catalyst
manufacturing insight and enhanced manufacturing techniques are employed in the production of
DeH-26 to create a custom-designed catalyst support. Platinum content is optimized for high yields
while maintaining excellent activity, ramp-up to full capacity is faster, and operators will enjoy shorter
startup times, longer run lengths and increased hydraulic capacity. The key benefits of this new
catalyst were designed in direct response to the needs of operators in the current market conditions.
The first commercial installation is expected to go online in an existing Oleflex unit in early 2019.
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The latest Oleflex process innovations that Honeywell is bringing to market are targeted to extend
on-stream time. Many operators today are looking for a four-year run length, mainly to allow for
synchronizing timing of planned shutdowns with other units. Operating at significantly lower
temperatures reduces carbonaceous fouling which, in turn, extends run length. UOP has achieved
this by further optimizing the conditions in the reactors to achieve the same conversions at lower
temperatures with a lower hydrogen-hydrocarbon ratio. This way the key benefits of low opex and
capex that come with Oleflex technology are maintained. A mechanical innovation providing
increased open area for vapor flow with the newest reactor internals increases the unit’s tolerance
for fouling, further extending the time on-stream before a constraint is reached and a maintenance
turnaround is required. Enhanced sulfur injection, optimized to synergize with the reactor
temperature profile improvements, reduces the potential for iron sulfide fouling and further extends
run length. All of these process design improvements are being incorporated into currently operating
Oleflex units and these features are standard in new Oleflex designs from 2018 forward.

Leading Technology in Practice

Great things happen when an operator partners with UOP. One operator partnered with UOP to
license and operate an Oleflex unit that started up over 10 years ago. The unit was designed for 350
kMTA production and achieved 100% of design. From startup through 2015, the operator worked
closely with UOP to optimize their Oleflex unit operations, selectively upgrading over the years with
the latest innovations that could be applied to their unit including the catalyst regeneration system,
reactor internals and fired heaters. During the most recent catalyst cycle from 2015 to present, out of
this close partnership with UOP, the unit routinely operated at 107% of design production capacity
while using 3% lower fresh propane feed than design. The unit has achieved a higher propylene
production rate at a lower operating cost due to the close partnership with UOP since startup,
resulting in more than a $5 million cost of production savings over the 2015-2018 period.
Additionally, when the unit was designed in 2003, the target run length between maintenance
turnarounds was 2 to 2.5 years. Like many other operators, this customer is interested in extending
cycle lengths and by applying select technology upgrades at the start of this most recent cycle, the
unit’s run length reached three years. UOP and the operator are working closely to incorporate further
upgrades targeting a four-year maintenance cycle length going forward.

A different operator saw great results when implementing the Process Reliability Advisor (PRA) from
the Honeywell Connected Plant. This Middle Eastern petrochemical complex with an Oleflex unit
strives to operate at peak performance to improve profitability while meeting demand. PRA enabled
them, in the first month, to increase process efficiency by over $1.2 million annually. Early event
detection and resolution with embedded root cause analysis, the ability to operate closer to
constraints and improve process performance by leveraging a digital twin of the process, and driving
best operating practices led to improved compressor efficiency, improved column operations, and
early warning of potential catalyst transfer issues.
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Review
The gap between propylene supply and demand has motivated on-purpose propylene production
since 2011. As demand continues to rise faster than supply, more units designed to produce
propylene continue to be commissioned. UOP’s Oleflex process is the leading on-purpose propylene
production process worldwide, with more than 75% of PDH projects and nearly 80% of all propane
or butane dehydrogenation projects awarded to UOP since 2011. Since 1990, nine customers have
commissioned multiple UOP Oleflex units, and nine customers have switched from a competitor’s
dehydrogenation unit to UOP Oleflex technology for the superior performance, reliability, and
profitability.
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For more information
For more information, please contact your UOP
representative or visit us online at www.uop.com. © 2019 UOP LLC. All rights reserved.
The information in this Honeywell
Company document should not be
construed as a representation for
UOP LLC, A Honeywell Company which UOP assumes legal
25 East Algonquin Road responsibility, or an authorization or
recommendation to practice a
Des Plaines, IL 60017-5017, U.S.A. patented invention without a license.
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