Propylene oxide, a commercially important chemical worldwide, is very reactive, finding application in many derivative businesses. Use is primarily as an intermediate for a wide array of products, such as polyether polyols for the polyurethane industry; propylene glycol for food, cosmetics, and heat‐transfer fluids; polyglycols as lubricants, antifoam agents, and metalworking fluids; glycol ethers for protective coatings, inks, and cleaners; and isopropanolamines for adhesives, corrosion inhibitors, and agricultural products.
Propylene oxide is produced by two process chemistries. The first, and oldest, is the chlorohydrin process. Epoxidation by caustic or milk of lime produces the epoxide. The second process involves the oxidation of an organic such as isobutane or ethylbenzene to the corresponding hydroperoxide, then epoxidation of propylene using the hydroperoxide to the epoxide and an alcohol. The alcohol,
tert
‐butanol or 1‐phenylethanol, is further processed to provide the commercially viable coproducts, such as methyl‐
tert
‐butyl ether and styrene. The global capacity for propylene oxide is about half from the chlorohydrin process and a quarter each from the hydroperoxide processes producing
tert
‐butanol and styrene as coproducts. These and several other potentially commercial processes are discussed.