Butadiene Production from n-Butane
Butadiene Production Costs Report | Issue A | Q3 2024
Report Details |
100 kta United States-based plant | Q3 2024 | 107 pages |
This report presents a cost analysis of a 100 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 1,3-Butadiene (BD) production from n-butane. In the process, n-butane undergoes a dehydrogenation reaction process similar to Lummus Catadiene, generating a C4s stream which is purified to obtain 1,3-Butadiene. The economic analysis is based on a plant located in the United States.
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 analysis comprises three major sections: (1) Dehydrogenation; (2) Cooling and Compression; and (3) Purification.
Dehydrogenation. Fresh butane is mixed with butane and butenes recovered downstream, and the mixture is then vaporized by heat exchange and heated in a gas fired charge heater. The feed stream is fed to a set of dehydrogenation reactors that operate in a defined sequence, on a cyclic basis, in such a way to permit continuous flow of the major process streams. The butane is converted to Butadiene while passing through fixed beds of chromia-alumina catalysts in the reactors. The dehydrogenation is carried out at 575 - 625 °C and 0.14 - 0.24 bar absolute. In each reactor cycle, after hydrocarbons dehydrogenation the reactor is purged with steam and blown with air, in order to reheat the catalyst and burn off coke deposited during the reaction.
Cooling and Compression. The hot effluent from the reactors is cooled by direct contact with a circulating quench oil stream. The quench oil absorbs polymeric compounds in the reactor effluent. The cooled effluent gas is compressed and partially condensed. The condensate is directed to distillation. The vapor is dried and, after chilling and condensation steps, C4+ are recovered and directed to distillation too.
Purification. Unreacted butane and butenes are partially removed from dehydrogenation product by conventional distillation. The butane and butenes are recycled to dehydrogenation. The stream rich in Butadiene, but still containing unreacted butane and butenes, is then submitted to extractive distillation in the presence of N-methylpyrrolidinone (NMP) used as solvent, yielding high purity Butadiene as the final product. Butane and butenes separated from the Butadiene are recycled to dehydrogenation.
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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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Details: 200 kta United States-based plant | Q3 2024 | 107 pages | Issue G From $999 USD
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Bio-Butadiene Production from Glucose (Anaerobic Fermentation)
It presents the economics of bio-based 1,3-Butadiene (BD) production from glucose syrup in the United States using an anaerobic fermentation process.
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The cost analyses presented in this report target a 165 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.
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