Paraxylene from Toluene (STDP with Pentasil Zeolite Catalyst)
p-Xylene Production Costs Report | Issue F | Q3 2024
Report Details |
400 kta United States-based plant | Q3 2024 | 107 pages |
This report presents a cost analysis of a 400 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 examines the costs related to a process for p-Xylene production from toluene in the United States. In this study, p-Xylene is produced via a selective toluene disproportionation process. High-purity benzene is also obtained as by-product.
The report provides a comprehensive study of p-Xylene production and related p-Xylene production cost, covering three key aspects: a complete description of the p-Xylene production process examined; an in-depth analysis of the related p-Xylene plant capital cost (Capex); and an evaluation of the respective p-Xylene plant operating costs (Opex).
The p-Xylene 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 p-Xylene 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 p-Xylene 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) Purification; and (3) Products Separation.
Reaction. Toluene and hydrogen feeds are combined and fed to a fired heater, where it is vaporized and raised to the reaction temperature. Here, the feed stream is fed to a radial reactor, where the disproportionation reaction takes place in vapor phase with a zeolitic catalyst (pentasil zeolitic aluminosilicate), in a hydrogen atmosphere to minimize coke formation and side reactions. This reaction proceeds via a bimolecular intermediate, which cleaves to benzene and xylene. The catalyst inhibits the diffusion of ortho-xylene and metaxylene is inhibited, promoting, ultimately, the formation of para-xylene.
Purification. The reactor effluent is cooled and routed to a gas/liquid separator, in which a hydrogen-rich gaseous stream is removed from the liquid stream, is compressed and recycled to feed. The liquid stream from the separator is fed to a column in which remaining gas and low-boiling hydrocarbons are stripped off from the stream. The aromatics concentrate is then submitted to a clay treatment, in such a way that impurities are removed by polymerization and absorption.
Products Separation. The aromatics concentrate is fractionated, so benzene, toluene and heavy aromatics are recovered. Toluene is recycled to feed stream. A concentrated xylenes stream is further divided into mixed xylenes and para-xylene by means of crystallizers and wash columns.
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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 p-Xylene 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 p-Xylene 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 p-Xylene 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 p-Xylene 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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