The STAR process

Dehydrogenation - The STAR process®

Based on our advanced, proven thyssenkrupp dehydrogenation technologies, the STAR process® and the STAR catalyst®, we can supply, from a single source, complete, optimized process routes to propylene and butylene derivatives, e.g. Polypropylene, Propylene Oxide, ETBE and other high-value products

The STAR process®, STAR being the acronym for Steam Active Reforming, is a commercially established dehydrogenation technology.

Propylene is a base petrochemical used for the production of, among other things, polypropylene (PP), oxo alcohols, acrylonitrile, acrylic acid (AA), propylene oxide (PO) and cumene.

About 60 % of the propylene produced today is used as feedstock for the production of PP.

With the STAR process®, thyssenkrupp Industrial Solutions can offer customers single-point responsibility for complete process routes to propylene derivatives, e.g. PP or PO, based on on-purpose propylene production from the dehydrogenation of propane and subsequent polymerization. The process economics of such production complexes are very favourable.

The hydrogen produced by dehydrogenation can be purified and used as feedstock for downstream plants (e.g. for H2O2 production by means of the Evonik-Uhde HPPO process), thus minimizing raw material costs.

Dehydrogenation of isobutane to isobutene for the production of MTBE is a commercially well-established process route. Although MTBE is no longer used in significant quantities in the USA, it is not clear if this will happen in other regions, too.

Other octane-boosting options are alkylates and dimers, which are used as blending stock to enhance the quality of unleaded gasoline to premium grade. Dehydrogenation of butanes to butenes can also be used for the production of these kinds of compounds.


High reaction operating pressure / low operating temperature

  • Fewer byproducts
  • Low compression costs

Highly efficient reaction section

  • Low catalyst inventory
  • In-situ regeneration

Fixed-bed reactor type

  • Simple, robust operation – less maintenance

No chemicals for catalyst activation or coke suppression

  • No environmental issues

High availability and reliabilit y

  • Independent parallel reactor trains

Short start-up and overall shut-down time

  • Simple to switch from regeneration to production mode
  • Shorter re-start from “hot stand-by”