Mixed Methylchlorosilanes Production
Chlorosilanes Production Costs Report | Issue A | Q2 2024
| Report Details |
| 180 kta United States-based plant | Q2 2024 | 107 pages |
This report presents a cost analysis of a 180 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 Mixed Methylchlorosilanes (mostly dimethyldichlorosilanes) production, starting from silicon and methyl chloride. The economic analysis approaches a plant located in the United States. In this process, methyl chloride and silicon powder are reacted in a fluidized bed reactor with copper catalyst, yielding the methylchlorosilanes.
The report provides a comprehensive study of Chlorosilanes production and related Chlorosilanes production cost, covering three key aspects: a complete description of the Chlorosilanes production process examined; an in-depth analysis of the related Chlorosilanes plant capital cost (Capex); and an evaluation of the respective Chlorosilanes plant operating costs (Opex).
The Chlorosilanes 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 Chlorosilanes 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 Chlorosilanes 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 two major sections: (1) Reaction; and (2) Products Separation.
Reaction. Silicon lumps are crushed in a jaw crusher, ground to silicon powder in a mill, and subsequently fed to the reactor. The reaction is carried out in a fluidized-bed reactor, in the presence of copper catalysts. Thorough mixing of the catalysts in the CH3Cl feed is of great important. Methyl chloride is vaporized and fed to the reactor as well. While such direct synthesis is strongly exothermic, reaction heat is removed by heat transfer oil circulating in a reactor cooling jacket and a heat exchanger inside the reactor. The hot heat transfer oil, in turn, is used to heat other operations in the process. As the reaction proceeds, silicon is consumed yielding a crude silane mixture. Silicon conversions of 90–98% are achieved.
Products Separation. The reaction effluent, still containing unreacted methyl chloride, is purified for the recovery of such reagent by means of two partial condensations. The methyl chloride is absorbed in chlorobenzene and stripped off from the solution formed upstream before it is recycled to the reaction. The crude silanes are then passed through multiple distillation columns, after which different silane monomers are obtained, according to the following distribution:
- 88.8 wt% of Dimethyldichlorosilane
- 5.1 wt% of Methyltrichloosilane
- 4.1 wt% of Trimethylchlorosilane
- 2.0 wt% of Methyldichlorosilane
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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 Chlorosilanes 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 Chlorosilanes 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 Chlorosilanes 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 Chlorosilanes 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: 3 kta United States-based plant | Q2 2024 | 107 pages | Issue B From $1,999 USD
The cost analyses presented in this report target a 3 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.
Vinylchlorosilanes Production
This report presents a techno-economic study of Vinylmethyldichlorosilane production using a conventional industrial process based on high temperature condensation of vinyl chloride with methyldichlorosilane. The economic analysis is based on a plant located in the United States.
Details: 1.50 kta United States-based plant | Q2 2024 | 107 pages | Issue C From $1,999 USD
The cost analyses presented in this report target a 1.50 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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