Propylene Production from Ethylene
Propylene Production Costs Report | Issue G | Q3 2024
| Report Details |
| 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.
Report Abstract
This study presents the economics of Polymer Grade (PG) Propylene production from ethylene in the United States similar to the one proposed by Lummus Technology. First, ethylene is dimerized into 2-butenes, which are then reacted with ethylene via a metathesis reaction, yielding propylene.
The report provides a comprehensive study of Propylene production and related Propylene production cost, covering three key aspects: a complete description of the Propylene production process examined; an in-depth analysis of the related Propylene plant capital cost (Capex); and an evaluation of the respective Propylene plant operating costs (Opex).
The Propylene 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 Propylene 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 Propylene 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 is divided into three main areas: (1) Dimerization; (2) Metathesis; and (3) Purification.
Dimerization. Fresh ethylene is mixed with catalyst and reactor circulating liquid and then fed to the reactor, which is a heat exchanger in the loop designed to remove the exothermic heat of reaction from the circulating liquid using cooling water. The main reaction is dimerization of ethylene to form n-butenes (primarily 2-butenes). The reactor product is quenched with caustic solution to stop the reaction. The catalyst quench system is designed to remove greater than 99.9% of the catalyst from the net dimerized product. The crude butene product is fed to the butene column with C4 recycle from the metathesis unit downstream. This column overhead is condensed sent as feed to the metathesis unit and the bottoms are sent to the heavy ends column, which is designed to distill gasoline blend by-product from the C5 and heavier components feeding the column.
Metathesis. Fresh and recycled ethylene and butenes are mixed and vaporized and heated to the reaction temperature, between 280-320 °C. The metathesis reaction occurs in a fixed bed catalytic reactor, butene is commonly employed in excess to minimize side reactions, which eventually occur, producing mostly C5-C8 olefins. Coke, another by-product of the reaction, is deposited on the catalyst throughout the process. Each reactor can run for about 30 days before requiring regeneration, in which coke is burned in a controlled atmosphere.
Purification. Propylene purification is carried out in two columns. The stream leaving the reactor is cooled and sent to the deethylenizer column, the overhead stream is recycled back to the reactor and the bottom stream is fed to the depropylenizer column which produces polymer grade propylene in the overhead and a heavies product stream (C4+) that is also recycled.
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Production Process Information
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Production Costs Datasheet
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Production Process Information
Process Consumptions
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Operating Cost Summary
Production Costs Datasheet
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Operating Cost Details
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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 Propylene 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 Propylene 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 Propylene 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 Propylene 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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