Production Cost Report
ICC - Is Bespoken: 0
ICC - Main References: ?
ICC - Issue: O
ICC - Volume: 172
ICC - Report ID: 172-O
ICC - Report Location: United States
ICC - Is Popular: 0
ICC - Is Developed: 1
ICC - Title: PG Ethylene from Ethanol (Similar to Scientific Design Process)
ICC - Show Overview: 1
ICC - Report Location ID: 1
ICC - Plant Capacity Unit ID: 14
ICC - Volume Reports List: 172-A,172-B,172-C,172-D,172-E,172-F,172-G,172-H,172-I,172-J,172-K,172-L,172-M,172-N,172-R,172-P,172-Q,172-S,172-T,172-U,172-V
ICC - Related Reports List: 230-A,198-F,110-B,110-A,241-E,241-C
ICC - Report Location Code: USA
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ICC - Prices: {"versions":{"1":{"1":"799","2":"799","3":"799"},"2":{"1":"1599","2":"1599","3":"1599"},"3":{"1":"2699","2":"2699","3":"2699"}},"currency":"USD"}
ICC - Plant Capacity Unit Name: kilo metric ton per annum
ICC - Plant Capacity Unit Short Name: kta
ICC - Process Overview Image: //cdn.intratec.us/images/icc/process-overview/172-O.jpg
ICC - Process Overview Text: <h6>Product</h6> <p><b>Ethylene</b>. 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.</p> <h6>Raw Materials</h6> <p><b>Chemicals</b>. </p> <b>Ethanol</b>. Ethanol, or ethyl alcohol, is a volatile, flammable, and colorless liquid (pure form). It is miscible in all proportions with water, ether, acetone, benzene, and some other organic solvents. Ethanol has been produced by the fermentation of carbohydrates for thousands of years. In the 1930s, low oil prices enabled the production of industrial ethanol through direct and indirect hydration of petroleum-derived ethylene. The rising cost of crude petroleum has prompted research into the industrial manufacture of ethanol from biomass sources. Ethanol from biomass can be produced by the fermentation of starch (from corn), sugar (from sugarcane) or waste lignocellulosic biomass (such as corn stover or switch grass). The process varies depending on the feedstock used. Due to governments’ programs and technology advances, biomass has become the lowest cost raw material for ethanol production. Currently, ethanol is almost exclusively obtained from biomass and has become a renewable-based chemical. Global concerns about sustainability and global warming have inspired research into the use of renewable ethanol for ethylene manufacture, substituting petroleum-derived ethylene.</p> <b>Caustic Soda</b>. Causic soda (NaOH), also known as sodium hydroxide, is a major inorganic used in several industries. Most of caustic soda production is used in the manufacture of chemicals, such as propylene oxide and sodium salts. Electrolysis of sodium chloride accounts for most of today’s installed capacity for caustic soda production, which also generates chlorine. </p>
ICC - Process Schematic Image: //cdn.intratec.us/images/icc/process-schematics/172-O.jpg
ICC - Process Schematic Text: <p>The process under analysis comprises four major sections: (1) Reaction; (2) Compression, Caustic Washing, and Drying; (3) Steam Generation; and (4) Purification.</p><p>Reaction. The ethanol stream is vaporized and superheated through heat integration with the reactor effluent. The superheated ethanol vapors are then mixed with steam and fed to the dehydration reactor. Once in contact with the fixed catalyst bed, the ethanol dehydration reaction occurs and the temperature drops. The hot reactor effluent is first cooled by the heat integration with reactor feed and then transferred to a partial condenser, in which most of the water is condensed by means of cooling water and transferred to the aldehyde stripper.</p><p>Compression, caustic washing, and drying. After reaction, the crude ethylene stream is compressed before entering the caustic washing column, where impurities are removed with a caustic solution. Process water is also supplied to this column to avoid caustic entrainment along with the ethylene overhead stream, which is cooled by interchange with the ethylene product stream. Water separated in the compression and cooling stages is sent to the aldehyde stripper. Next, the gas stream is dehydrated in a molecular sieve unit.</p><p>Steam Generation. In this column, residual aldehydes are separated from condensed water. Aldehydes are recovered as the overheads vapor product and directed to the furnace to be used as fuel. A portion of the condensed water is discarded as wastewater, while the remainder is vaporized. The steam, also containing small amounts of unconverted ethanol, is heated by heat exchange with reactor effluent. The superheated steam is then fed in to the furnace for the last superheating step. The superheated steam is sent to the inlet of the reactor to be mixed with superheated ethanol. </p><p>Purification. The dehydrated stream is fed into the ethylene column, where heavy residues are removed. Next, carbon monoxide is removed in the stripper column. The two columns share a single condenser, which uses propylene refrigerant. The polymer grade ethylene (99.9 wt%) product is obtained in the bottoms of the stripper column and used to cool process streams in heat integrations.</p>
ICC - Short Description: This report approaches the economics of Green Polymer Grade (PG) Ethylene production from hydrous ethanol using a dehydration process similar to the process developed by Scientific Design. In this process, the reaction system is composed of only one reactor and one furnace. The study also assumes a plant constructed in the United States.
ICC - Main Product: Ethylene
ICC - Plant Capacity: 250.00
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PG Ethylene from Ethanol (Similar to Scientific Design Process)

Ethylene Production Costs Report | Issue O | Q3 2024

Production Cost Report

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250 kta United States-based plant   |   Q3 2024   |   107 pages

This report presents a cost analysis of a 250 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.

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Production Process Information

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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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CG Ethylene Production from Ethanol

This report approaches the economics of Green Chemical Grade (CG) Ethylene production from hydrous ethanol using a dehydration process similar to the process developed by Scientific Design. In this process, the reaction system is composed of only one reactor and one furnace. The study assumes a plant constructed in the United States.

Details: 250 kta United States-based plant   |   Q3 2024   |   107 pages   |   Issue Q   From $799 USD

The cost analyses presented in this report target a 250 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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