Production Cost Report
ICC - Is Bespoken: 0
ICC - Main References: (1) US Patent 8440874, issued to Lummus Technology and BASF in 2013 (2) US Patent 20050124839, issued to Lummus Technology in 2005
ICC - Issue: A
ICC - Volume: 230
ICC - Report ID: 230-A
ICC - Report Location: United States
ICC - Is Popular: 0
ICC - Is Developed: 1
ICC - Title: Propylene Production from Ethylene and Butenes
ICC - Show Overview: 1
ICC - Report Location ID: 1
ICC - Plant Capacity Unit ID: 14
ICC - Volume Reports List: 230-B,230-C,230-D,230-E,230-G,230-H,230-I,230-J,230-L,230-M,230-F,230-K,230-N
ICC - Related Reports List: 172-A,199-A,172-B,199-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/230-A.jpg
ICC - Process Overview Text: <h6>Products</h6> <p><b>Propylene</b>. Propylene, the main raw material consumed, is a colorless gas at room temperature. It is a low-boiling, flammable, and highly volatile gas, with molecular formula C3H6. Propylene reacts vigorously with oxidizing materials. It may be mildly irritating to the nose, throat, and respiratory tract; propylene has low acute toxicity from inhalation. PG Propylene has been mainly produced as ethylene manufacturing co-product (via steam cracking of paraffinic hydrocarbons) and by-product of petroleum refining (separation from refinery gas). Most recently, amid a tight propylene market, new and novel lower-cost chemical processes for on-purpose propylene production have emerged.</p> <p><b>Fuel</b>. </p> <h6>Raw Materials</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> <b>Raffinate-2</b>. Raffinate-2 is a C4 residual stream primarily consisting of 1-butene, 2-butenes, and butanes. It is obtained following the separation of 1,3-butadiene and isobutylene from mixed C4s stream (or crude C4s), which is one of the products of the naphtha steam cracking processes.</p>
ICC - Process Schematic Image: //cdn.intratec.us/images/icc/process-schematics/230-A.jpg
ICC - Process Schematic Text: <p>The process is divided into two main areas: (1) purification & reaction; and (2) separation.</p><p>Purification & reaction. Fresh and recycled ethylene and butene are mixed and fed to the treaters in order to remove potential catalyst poisons such as oxygenates and sulfur. After treatment, the stream is 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.</p><p>Separation section. 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.</p>
ICC - Short Description: This report presents the economics of Polymer Grade (PG) Propylene production from ethylene and raffinate-2. The process under analysis consists in a metathesis process similar to Lummus Technology's Olefins Conversion Technology (OCT). The economic analysis performed assumes a plant located in the United States.
ICC - Main Product: Propylene
ICC - Plant Capacity: 350.00
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Propylene Production from Ethylene and Butenes

Propylene Production Costs Report | Issue A | Q3 2024

Production Cost Report

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

This report presents a cost analysis of a 350 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

Process Consumptions

Labor Requirements

Plant Capital Cost Summary

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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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This report examines the costs related to Polymer Grade (PG) Propylene production from refinery grade (RG) propylene, via a typical purification process. Propane stream is generated as by-product. The economic analysis performed assumes a plant located in the United States.

Details: 400 kta United States-based plant   |   Q3 2024   |   107 pages   |   Issue J   From $799 USD

The cost analyses presented in this report target a 400 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.

Propylene Production from Butenes

This report analyses the economics of Polymer Grade (PG) Propylene production from raffinate-1 in the United States, using two typical integrated processes: isomerization and metathesis. In these processes, 1-butene present in raffinate-1 is isomerized into 2-butenes. The 2-butenes are submitted with ethylene to a metathesis reaction, producing propylene. A C5s stream is generated as by-product.

Details: 480 kta United States-based plant   |   Q3 2024   |   107 pages   |   Issue K   From $1,199 USD

The cost analyses presented in this report target a 480 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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Ethylene Production from Naphtha (Low Severity Steam Cracking)

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.

Details: 800 kta Germany-based plant   |   Q3 2024   |   107 pages   |   Issue A   From $799 USD

The cost analyses presented in this report target a 800 kta (kilo metric ton per annum per annum) Germany-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

Ethylene Production from Ethane

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Details: 1,200 kta United States-based plant   |   Q3 2024   |   107 pages   |   Issue B   From $799 USD

The cost analyses presented in this report target a 1,200 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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Details: 350 kta United States-based plant   |   Q3 2024   |   107 pages   |   Issue A   From $799 USD

The cost analyses presented in this report target a 350 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.

PP Homopolymer from Propylene (Spherizone)

This report examines the costs related to Polypropylene (PP) Homopolymer production from polymer grade (PG) propylene, using a gas phase polymerization process similar to LyondellBasell Spherizone. The reaction occurs in a multi-zone circulating reactor (MZCR). The economic analysis performed assumes a plant located in the United States.

Details: 350 kta United States-based plant   |   Q3 2024   |   107 pages   |   Issue C   From $799 USD

The cost analyses presented in this report target a 350 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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