Summary of the 8 Major PDH Processes! (Practical Insights)

This process employs a multitubular fixed-bed reactor with a Cr2O3/Al2O3 catalyst, operating at 590°C and above 0.1 MPa pressure, achieving propane conversion exceeding 90%. Subsequently, BASF developed a Pt/zeolite catalyst; compared to the first-generation Cr-based catalyst, single-pass conversion increased from 32% to 50%, and overall conversion rose from 91% to 93%. However, no industrial application has been reported to date. 6. China University of Petroleum’s Propane/Butane Combined Dehydrogenation (ADHO) Technology The ADHO technology utilizes non-toxic, non-corrosive non-precious metal oxide catalysts, coupled with an efficiently designed circulating fluidized-bed reactor. Its single-pass alkane conversion, olefin yield, and selectivity are comparable to those of the FBD technology. An industrial-scale pilot test was completed in June 2016 at Shandong Hengyuan Petrochemical Group Co., Ltd. 7. Dow’s Fluidized Catalytic Dehydrogenation (FCDh) Process Introduced by U.S.-based Dow Chemical Company in 2017, the FCDh technology employs a fluidized-bed reactor and a Ga/minor Pt–Al2O3 catalyst. Operating at 0.13–0.17 MPa, it achieves 43%–48% propane conversion with 92%–96% propylene selectivity. Compared with currently leading fixed-bed PDH technologies, FCDh offers faster reaction kinetics, eliminates the need for hydrogen recycle, requires smaller reactor equipment, exhibits excellent catalyst stability, features lower initial catalyst loading, and uses less precious metal—resulting in lower capital expenditure. This process can be integrated with ethylene steam crackers. In 2019, Dow announced an upgrade to its steam cracker facility in Plaquemine, Louisiana, incorporating FCDh to add 100,000 tons/year of dedicated propylene capacity; the project is expected to commence operation in 2021. 8. KBR’s K-PRO Process KBR launched its novel PDH process, K-PRO, in 2018. It employs a coaxial continuous reactor with a proprietary non-Cr/non-Pt catalyst and enables continuous catalyst regeneration. Propylene selectivity reaches 87%–90%, with propane conversion up to 45%. Compared with fixed-bed or moving-bed reactors, K-PRO reduces capital investment by 20%–30%. In January 2020, K-PRO received its first license for a 600,000-ton/year PDH unit in Asia. Table 2: Statistics on PDH Technologies Adopted by Selected Domestic Projects (2019–2022) Company Capacity (tons/year) Technology Tianjin Bohua (Phase II) 600,000 Catofin Satellite Chemical (Phase II) 450,000 Oleflex Meide Petrochemical (Phase I) 660,000 Oleflex Zhejiang Petrochemical (Phase I) 600,000 Oleflex Ju Zhengyuan (Phase I) 600,000 Catofin Guangdong Pengzun 450,000 Catofin Minggang Chemical 600,000 Oleflex Hebei Haiwei (Phase II) 500,000 Catofin Wanda Tianhong 450,000 Oleflex Zhejiang Huahong 450,000 Oleflex Wanhua Chemical (Phase II) 500,000 Oleflex Wu Di Senyue 600,000 Oleflex Jiangsu Jiarui Chemical 2 × 450,000 Oleflex

Dow’s 2021 PE Innovation Solutions Summary

What outstanding achievements did Dow make in 2021 regarding high-end polyethylene (PE), PE elastomers, PE application development, bio-based PE, and low-carbon PE? As one of the world’s leading producers of high-end polyethylene, how will Dow’s PE development strategy evolve amid the low-carbon and zero-carbon era? “Net-Zero Carbon” Ethylene Cracker Complex Dow announced plans to build the world’s first “net-zero carbon” ethylene cracker and derivatives integrated complex at its Fort Saskatchewan site in Alberta, Canada. Dow will more than triple ethylene and polyethylene capacity at this site while retrofitting existing facilities to achieve net-zero carbon emissions. This investment will decarbonize approximately 20% of Dow’s global ethylene capacity, increase its polyethylene supply capacity by about 15%, and boost EBITDA across its entire value chain by roughly USD 1 billion by 2030. Ethane Dehydrogenation (EDH) and Electric Cracking (e-Cracking) Technologies Dow is advancing ethane dehydrogenation (EDH) and electric cracking (e-cracking) technologies to reduce carbon emissions from existing crackers—and ultimately achieve zero emissions. Ethane Dehydrogenation (EDH) Technology ■ Dow will leverage its proprietary technology to develop EDH, while also evaluating potential technology suppliers—including Eco Catalyst Technologies. ■ Dow’s EDH technology builds upon its UNIFINITY fluidized catalytic dehydrogenation (FCDh) technology. A mixed-feed cracker at Dow’s Plaquemine, Louisiana facility will adopt FCDh, enabling production of 100,000 tons/year of dedicated propylene after revamp. Construction is scheduled to begin in 2021, with startup targeted for 2022. ■ In 2022, Dow will continue R&D on ethylene and propylene technologies, with the ultimate goal of producing ethylene from ethane via EDH on cracker units. Electric Cracking (e-Cracking) Technology ■ In June 2020, Dow and Shell announced a joint development agreement to accelerate the commercialization of new electrification technologies for ethylene steam crackers. ■ Currently, steam crackers rely on fossil fuel combustion to heat cracking furnaces, generating substantial CO₂ emissions. As power grids shift toward renewable energy dominance, heating steam cracking furnaces using renewable electricity may become a primary pathway for reducing carbon emissions in the chemical industry. ■ Integrating EDH with e-cracking could reduce CO₂ emissions by 40%–50%. ■ Dow aims to achieve carbon neutrality by 2050 through deployment of such technologies. Dow’s Bio-Based Polyolefin Elastomer Henkel launched Technomelt Supra ECO—a new series of hot-melt adhesives. Reportedly, it retains the performance attributes of the Supra series while offering enhanced sustainability and lower carbon emissions. This product line was co-developed with Dow Chemical Company, which supplied AFFINITY™ RE bio-based polyolefin elastomer—a material capable of effectively replacing fossil-based alternatives. The International Sustainability and Carbon Certification (ISCC) scheme ensures traceable sourcing, thereby providing packaging manufacturers with a reliable means to substantiate their sustainability goals.

Dow and American Electric Power Reach Agreement to Develop New Cogeneration Plant to Serve Dow in Plaquemine, LA

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Dow Inc and American Electric Power finalized an agreement to construct a $325 million natural gas-fired cogeneration plant at Dow's Plaquemine facility. The plant will begin operations in early 2003, supplying steam and electricity while selling excess output to Tractebel Energy Marketing.

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