Ethylene Production from Naphtha (Low Severity Steam Cracking)
Ethylene Production Costs Report | Issue A | Q2 2024
| Report Details |
| 800 kta Germany-based plant | Q2 2024 | 107 pages |
This report presents a cost analysis of a 800 kta (kilo metric ton per annum) Germany-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 a naphtha-based steam cracker, equipped with an electricity cogeneration unit. In this process, naphtha is thermally cracked at low severity conditions, maximizing propylene to Ethylene ratio. The analysis is based on a plant located in Germany.
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) Cracking and Quenching; (2) Compression and Drying; and (3) Separation.
Cracking & Quenching. After a pre-treatment step, naphtha is fed to furnaces where it is cracked into ethylene, propylene and by-products. The furnace effluent is fed to the Primary Fractionator, where fuel oil by-product is withdrawn from its bottom. The overhead cracked gas is cooled in a quench tower and the condensate is sent to a decanter, where pyrolysis gasoline is removed from water and sent to storage. Cracked gas from the quench is sent to compression.
Compression & Drying. The compression of the cracked gas is performed across 5 stages. After the third stage, carbon dioxide and sulfur are removed from cracked gas. The compressed cracked gas is cooled and dried - most of the water is removed.
Separation. The dry cracked gas is fed to a cold box to remove hydrogen and light hydrocarbons. Condensates from the chilling train are fed to the demethanizer, where methane is obtained from the top and reused in the cold box. The demethanizer bottoms stream is fed to a series of columns, from which high-purity Ethylene is obtained. During the purification steps the following by-products are also obtained: polymer-grade propylene, Mixed C4 and a second portion of pyrolysis gasoline.
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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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