Butadiene Production from Ethanol
Butadiene Production Costs Report | Issue C | Q2 2024
Report Details |
110 kta United States-based plant | Q2 2024 | 107 pages | Delivered in PDF |
This report presents a cost analysis of a 110 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 examines the costs related to 1,3-Butadiene (BD) production from hydrous ethanol in the United States. This process consists of a two-stage reaction process. First, ethanol is converted to acetaldehyde, which is then reacted with ethanol to produce 1,3-Butadiene. Raffinate is generated as by-product in the process.
The report provides a comprehensive study of Butadiene production and related Butadiene production cost, covering three key aspects: a complete description of the Butadiene production process examined; an in-depth analysis of the related Butadiene plant capital cost (Capex); and an evaluation of the respective Butadiene plant operating costs (Opex).
The Butadiene 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 Butadiene 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 Butadiene 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 review comprises four main sections: (1) Acetaldehyde Conversion; (2) Butadiene Conversion; (3) Butadiene Recovery & Purification; (4) Ethanol and Acetaldehyde Recovery.
Acetaldehyde Conversion. Ethanol vapors are fed to a reactor where the dehydrogenation reaction occurs, catalyzed by a copper catalyst that produces acetaldehyde and hydrogen. The reactor effluent is then partially condensed. The non-condensed phase is scrubbed to recover the acetaldehyde from the gas phase containing hydrogen and light by-products. Part of the acetaldehyde-rich condensate is sent to purification steps, while the other fraction is used as a solvent in the butadiene scrubber.
Butadiene Conversion. Acetaldehyde is mixed with ethanol and fed to a second reactor where the condensation reaction occurs to produce Butadiene, with tantalum oxide as the catalyst. The products of this reaction are also partially condensed. Most of the Butadiene remains in the condensate, which is sent to downstream purification steps. The non-condensed phase passes through two scrubbers. The first one uses an ethanol-acetaldehyde mixture to recover the Butadiene, and the second scrubber uses water as solvent to recover the unreacted ethanol and acetaldehyde.
Butadiene Recovery & Purification. The solution containing the Butadiene produced is fed to a distillation column followed by a scrubber. The resulting Butadiene-rich stream is then sent to an extractive distillation system. Finally, a pre-purified Butadiene stream from the extractive distillation area is fed to a distillation column so as to recover a purified Butadiene product (with 99.6 wt% of purity).
Ethanol and Acetaldehyde Recovery. In this section the liquid streams from scrubbers and product recovery steps are fed to a sequence of three distillation columns to recover unreacted acetaldehyde and ethanol from by-products generated throughout the process due to side reactions.
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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 Butadiene 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 Butadiene 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 Butadiene 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 Butadiene 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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