Ethylene Dichloride from Ethylene and Chlorine (HTC with Distillation)
Ethylene Dichloride Production Costs Report | Issue A | Q2 2024
Report Details |
500 kta United States-based plant | Q2 2024 | 107 pages |
This report presents a cost analysis of a 500 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 a techno-economic analysis of Ethylene Dichloride (EDC) production from ethylene and chlorine in the United States using a direct chlorination process consisting in a liquid-phase high temperature chlorination (HTC). In this process, ethylene is chlorinated to EDC in liquid phase, using EDC itself as the solvent.
The report provides a comprehensive study of Ethylene Dichloride production and related Ethylene Dichloride production cost, covering three key aspects: a complete description of the Ethylene Dichloride production process examined; an in-depth analysis of the related Ethylene Dichloride plant capital cost (Capex); and an evaluation of the respective Ethylene Dichloride plant operating costs (Opex).
The Ethylene Dichloride 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 Ethylene Dichloride 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 Ethylene Dichloride 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) Direct Chlorination; and (2) Purification.
Direct Chlorination. Chlorine and ethylene are fed to a high-temperature chlorination (HTC) reactor, filled with EDC as the reaction medium. The heat of the highly exothermal reaction is removed by boiling off EDC, and by the circulation of EDC which is recycled from the Product Column downstream. Ferric chloride (FeCl3) is used as catalyst. About 99% of ethylene and almost 100% of chlorine are converted, with high selectivity to EDC. Unavoidable side reactions generate polychlorinated compounds as by-products, mainly 1,1,2-trichloroethane. Among such by-products, the ones with boiling points higher than EDC are primarily withdrawn from the bottom of the reactor as a liquid stream. The gaseous effluent from the chlorination, containing the EDC product, is routed to purification steps downstream.
Purification. In this area, the gaseous effluent rich in EDC is passed through a heat exchanger, where it generates steam while being partially condensed by boiler feed water. The EDC-rich stream is then fed to a distillation column, where it is purified from residual by-products. The stream withdrawn from column overhead is then cooled in a cooling water condenser, yielding a liquid stream composed of EDC 99.5 wt% that is pumped to storage facilities located outside battery limits. Not condensed gases – mainly ethylene, nitrogen, chlorine, HCl, and residual water and EDC – are then passed through a second condenser using refrigerant fluid. After such second condensation step, uncondensed gases are routed to an incinerator located outside battery limits. The column bottom product composed of EDC and some polychlorinated compounds is recycled to the Direct Chlorination reactor. Part of this stream is purged to avoid the build-up of impurities.
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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 Ethylene Dichloride 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 Ethylene Dichloride 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 Ethylene Dichloride 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 Ethylene Dichloride 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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