1-Hexene Production from Ethylene
Hexene Production Costs Report | Issue A | Q3 2024
| Report Details |
| 200 kta United States-based plant | Q3 2024 | 107 pages |
This report presents a cost analysis of a 200 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 the economics of an industrial process for 1-Hexene production from ethylene, assuming a trimerization process similar to the one owned by Chevron Philips. The economic analysis is based on a plant operating in the United States.
The report provides a comprehensive study of Hexene production and related Hexene production cost, covering three key aspects: a complete description of the Hexene production process examined; an in-depth analysis of the related Hexene plant capital cost (Capex); and an evaluation of the respective Hexene plant operating costs (Opex).
The Hexene 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 Hexene 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 Hexene 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) Reaction; (2) Chemicals Separation; and (3) Purification.
Reaction. A recycle cyclohexane stream from the Solvent Recovery Column is mixed with the catalyst system solution and then fed a trimerization reactor. An ethylene recycle stream is mixed with the ethylene feed and they are simultaneously fed to the reactor, but in a counter-current fashion. In order to remove the reaction heat from the medium, it is maintained an external circulation loop passing through heat exchangers against boiler feed water, generating low pressure steam. The process achieves an ethylene conversion of about 70 wt%.
Chemicals Separation. The reactor output stream is mixed, in a static mixer, with 2-ethyl-1-hexanol, which deactivates the catalyst in the reaction medium, to prevent the production of by-products during the purification section. Then the deactivated process stream is flashed in three stages, at decreasing pressures and increasing temperatures. The recovered vapor phases from each stage are mixed and directed to the Ethylene Recovery Column. As a result, a relatively pure ethylene stream is recovered as the top product and most of it is recycled to reaction. The smaller part is purged from the process to avoid the buildup of light contaminants in the process.
Purification. The product rich stream is fed to another three distillation columns in order to separate heavy olefins by-products produced via undesirable side reactions and lighter contaminants, which are exported to the nearby petrochemical complex to be used as fuel. A cyclohexane rich stream is also recovered and split into two fractions, one fraction is directed to the reaction area and the second fraction is sent to the Ethylene Recovery Column. The final product stream, with a purity greater than 99 wt%, is produced.
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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 Hexene 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 Hexene 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 Hexene 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 Hexene 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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