Acetylene Production from Natural Gas (Partial Combustion Process)
Acetylene Production Costs Report | Issue A | Q3 2024
| Report Details |
| 50 kta United States-based plant | Q3 2024 | 107 pages |
This report presents a cost analysis of a 50 kta (kilo metric ton per annum) United States-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.
Report Abstract
This report presents the economics of Acetylene production from natural gas using a partial combustion process similar to that developed by BASF. In this process, methane from natural gas is cracked in high temperatures to acetylene and hydrogen. The economic analysis developed is based on a plant constructed in the United States.
The report provides a comprehensive study of Acetylene production and related Acetylene production cost, covering three key aspects: a complete description of the Acetylene production process examined; an in-depth analysis of the related Acetylene plant capital cost (Capex); and an evaluation of the respective Acetylene plant operating costs (Opex).
The Acetylene production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The Acetylene plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The Acetylene plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Process Schematic
The process under analysis comprises three major sections: (1) Reaction; (2) Purification; and (3) Solvent recovery.
Reaction. Initially, the natural gas feed and oxygen are preheated and fed to a burner, which consists of a watercooled steel plate with several small combustion channels. The preheating reduces the consumption of oxygen and hydrocarbon within the burner. Approximately two-thirds of the methane is burned, while the remainder is cracked to Acetylene. The hot gas leaves the reaction chamber after a few milliseconds, at the optimum yield of acetylene, and is promptly cooled down with water (quench system).
Purification. Soot present in the cracked gas, formed in the reaction chamber, is partly removed from the gas by the water quench, with the remainder being removed by a recirculated water wash in a cooling column. The gaseous outlet is compressed and Acetylene is recovered by selective absorption into N-methylpyrrolidinone (NMP) solvent in the main scrubber. This column off-gas is a crude synthesis gas stream. The Acetylene solution is subsequently vacuum stripped to recover the gas, which is then scrubbed with acid and caustic solutions to attain the desired purity. The purified Acetylene is finally sent to consumers.
Solvent recovery. The NMP solution must be degassed in multiples steps at reducing pressures and increasing temperatures. NMP solvent is completely degassed and proper for reuse in the main scrubber. The remaining vapor stream, comprising mainly higher acetylenes, is used as fuel gas.
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Production Process Information
Process Consumptions
Labor Requirements
Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
Plant Capital Cost Details
Operating Cost Details
Plant Cost Breakdowns
Plant Capacity Assessment
Process Flow Diagrams
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Acetylene production plant examined
Plant Capital Cost Details
Detailing of fixed capital (ISBL, OSBL & Owner’s Cost), working capital and additional capital requirements
Plant Cost Breakdowns
Breakdown of Acetylene process unit (ISBL) costs and infrastructure (OSBL) costs; plant cost breakdown per discipline
Operating Costs Summary
Summary presenting the operating variable costs and the total operating cost of the Acetylene production plant studied
Operating Cost Details
Detailing of utilities costs, operating fixed costs and depreciation
Plant Capacity Assessment
Comparative analysis of capital investment and operating costs for different Acetylene plant capacities
Production Process Information
Block Flow Diagram, descriptions of process unit (ISBL) and site infrastructure (OSBL)
Process Consumptions
Raw materials and utilities consumption figures, by-products credits, labor requirements
Process Diagrams
Process flow diagrams (PFD), equipment list and industrial site configuration
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