Ethylene from PVC-Rich Mixed Plastic Waste
Ethylene Production Costs Report | Issue T | Q3 2024
| Report Details |
| 30 kta United States-based plant | Q3 2024 | 107 pages |
This report presents a cost analysis of a 30 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 provides an economic analysis of Ethylene production via pyrolysis of mixed plastic waste rich in PVC in the United States. Initially, the chlorine content in the main stream is removed by reacting it with calcium carbonate. Then, the chlorine-depleted plastic stream is submitted to pyrolysis. The resulting pyrolysis gases are first sent to primary separation and finally distilled, yielding ethylene and other by-products.
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 Overview
Products
Ethylene. Ethylene is known as a key building block for the petrochemical industry, being one of the largest-volume petrochemical produced worldwide. It is widely used as chemical intermediate in the production of several end products, including plastics, resins and fibers. Ethylene is largely produced by thermal cracking of petroleum-based feedstocks, in the presence of steam. It is stored in a liquid state under high pressure or at low temperatures. However, ethylene is, most of times, directly supplied to its consumers.
Propylene. Propylene, the main raw material consumed, is a colorless gas at room temperature. It is a low-boiling, flammable, and highly volatile gas, with molecular formula C3H6. Propylene reacts vigorously with oxidizing materials. It may be mildly irritating to the nose, throat, and respiratory tract; propylene has low acute toxicity from inhalation. PG Propylene has been mainly produced as ethylene manufacturing co-product (via steam cracking of paraffinic hydrocarbons) and by-product of petroleum refining (separation from refinery gas). Most recently, amid a tight propylene market, new and novel lower-cost chemical processes for on-purpose propylene production have emerged.
Raw Materials
Calcium Carbonate. Calcium Carbonate (CaCO3) is a compound commonly found as a white mineral (calcite) which occurs naturally in chalks, limestones and marbles. These rocks are classified as limestones, a general term used for a rock containing varying proportions of calcite and dolomite. The quality of calcium carbonate depends on some factors: purity, whiteness, homogeneity, and thickness.
Mixed Plastic Waste. Mixed Plastic Waste (70 wt% PE/PP, 6.5 wt% PVC, 13.5 wt% PS, 10 wt% rest) consists of a blend of polyolefins and other plastic types, primarily used in waste-to-energy processes or low-grade recycling. This mixture's varied composition poses challenges for traditional recycling, but it serves as feedstock for chemical recycling or alternative fuels, reducing the reliance on fossil resources.
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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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