Ethylene oxide/ethylene glycol (EO/EG) processes

Award-winning technology aims to help meet growing demand

The market for EO, about three-quarters of which is converted to EG, is expected to grow at around 5% per
year. In January 2014 there were 127 plants producing over 26 Mt/y of EO equivalents. However, the EO
derivatives market is highly competitive, and low-cost producers are best positioned for long-term business
strength. As well as low feedstock prices and large plant capacities, the application of best-available
technology is also of key importance..
About the technology
Shell Global Solutions works with customers to develop safe, cost-effective designs that are tuned to meet
local market conditions and customers needs. The organisation is one of the markets leading EO/EG
process licensors.
Moreover, the Shell Group (Shell) is a major producer of EO and EG through its production facilities in
Canada, China, the Netherlands, Singapore and the USA. CRI Catalyst Company (CRI) is the leading EO
catalyst producer and a pioneer in the industry. For more than 50 years, CRI and Shell have led the industry
in improving the performance and lifespan of EO catalysts. Over 50% of the worlds current EO production is
manufactured using a CRI EO catalyst.
Process description

Figure 1: The selective MEG technology, combined with the application of a high-selectivity EO catalyst,
results in the lowest ethylene consumption per tonne of MEG ever achieved in the industry. Energy
consumption, wastewater production and capital costs are also reduced.
Two versions of the Shell EO/EG process are licensed:

the Shell MASTER process, which is based on a high-selectivity EO catalyst and thermal conversion
of EO to EG; and

the Shell OMEGA process, which is based on highselectivity EO catalyst and monoethylene glycol
(MEG) only technology.

In the Shell MASTER process, EO and water are converted to glycols by thermal hydration in a tubular
reactor. This process yields roughly 810% diethylene glycol (DEG) and triethylene glycol (TEG). The MEG
yield depends on the amount of water used in the reaction. Excess water is removed by multiple-effect
evaporation, and the individual glycol products are then recovered and purified by distillation.
In the Shell OMEGA process, EO is first reacted with carbon dioxide to form ethylene carbonate, which is
then hydrolysed to MEG and carbon dioxide (Figure 1 overleaf). As EO is not present in the hydrolysis
reaction, the co-production of DEG and heavier glycols is negligible. Both processes have the option to coproduce high-purity EO.
Performance data
Plant design is optimised to leverage state-of-the-art, highselectivity EO catalysts and enables at least three
years operation between catalyst changes at an average catalyst selectivity of about 90%.
The Shell MASTER process makes use of CRIs latest high-selectivity EO catalyst that can run for three years
at about 90% average selectivity. Longer run lengths can also be accommodated. The process co-produces
DEG and TEG. The MEG yield is typically 9092%, depending on customer requirements.
The Shell OMEGA process also uses CRI high-selectivity EO catalyst, and offers significant advantages
compared with conventional processes. For instance, it:

has a MEG selectivity in excess of 99%, which means that virtually no lower-value DEG or TEG is
produced;

produces superior-quality product;

uses about 20% less steam at equal EO selectivity; and

produces 30% less waste water.

In addition, a Shell OMEGA plant costs 10% less to build for the same yield.
Proof Points
Since Shell started licensing its EO/EG technology in 1956, more than 70 Shell-designed EO/EG units were
commissioned or are currently under construction.
The Shell OMEGA process was acclaimed in the prestigious IChemE Innovation and Excellence Awards 2008
by winning the Engineering Excellence Award.
Business value

As every plant is tailor-made and tuned to customer wishes and local conditions and constraints, capital
investment costs will vary from plant to plant. In 2004, the capital costs of a 600-kt/y MEG unit were
estimated at $120160 million for the inside-battery-limits portion, but construction and material prices
have increased significantly since. After plant start-up, Shell and CRI will continue to provide operational
support. Process design studies relating to plant modifications or debottlenecking can also be
accommodated.