Ethylene from Ethanol (Similar to Hummingbird Process)
Ethylene Production Costs Report | Issue I | Q3 2024
| Report Details |
| 210 kta United States-based plant | Q3 2024 | 107 pages |
This report presents a cost analysis of a 210 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 study presents a techno-economic analysis of Green PG Ethylene production from hydrous ethanol in the United States using a dehydration process similar to the TechnipFMC’s Hummingbird process (former BP Chemicals). The reaction is carried out in multiple stage reactors with inter stage heaters in vapor phase.
The report provides a comprehensive study of Ethylene production and related Ethylene production cost, covering three key aspects: a complete description of the Ethylene production process examined; an in-depth analysis of the related Ethylene plant capital cost (Capex); and an evaluation of the respective Ethylene plant operating costs (Opex).
The Ethylene 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 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 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) Feed treatment; (2) Reaction; and (3) Purification.
Feed treatment. Fresh ethanol feed, containing about 6 wt% water, is combined with recycled ethanol and diethyl ether recovered in distillation columns downstream, and fed to a distillation column for removal of small amounts of unwanted by-products such as acetaldehyde and C4 hydrocarbons (primarily butylenes) that were generated in the reaction. The resulting overhead stream from this column is burned as fuel.
Reaction. The bottoms stream from the feed treatment column, containing mainly ethanol and diethyl ether, is vaporized and fed to the first of four superheaters. After being vaporized and superheated, the mixture is fed to the first of four adiabatic fixed-bed reactors, containing heteropolyacid catalyst supported on silica. The superheaters provide the heat consumed by the endothermic reaction that occurs in the reactors. Each superheater is located before one of the four reaction stages, ensuring that the reaction stage inlet temperature is 240 °C. While the ethanol dehydration is carried out at high temperatures, some thermal cracking reactions may occur, generating undesirable by-products such as alkanes.
Purification. The reaction outlet stream primarily consists of unreacted ethanol, Ethylene, and diethyl ether. The stream is sent to a series of columns for Ethylene purification. The first column is mainly used to separate the Ethylene from the water formed in ethanol dehydration. The second column aims to separate diethyl ether. The distillate product is polymer grade Ethylene. The diethyl ether-rich bottoms product is recycled to the feed treatment. The bottoms stream from the first column - rich in water, ethanol and diethyl ether - is transferred to the dewatering column. Water is extracted, while mostly unreacted ethanol and diethyl ether are also recycled.
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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 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 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 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 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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