Vinyl Chloride from Ethylene and Chlorine (Balanced Process)
Vinyl Chloride Production Costs Report | Issue D | Q2 2024
| Report Details |
| 500 kta United States-based plant | Q2 2024 | 107 pages |
This report presents a cost analysis of a 500 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 Vinyl Chloride (VCM) production from ethylene and chlorine in the United States. Initially, ethylene is chlorinated to produce ethylene dichloride (EDC). Then, EDC is thermally cracked yielding VCM and HCl. The HCl produced and ethylene are reacted with oxygen, yielding more EDC. This leads to a so called “balanced process”.
The report provides a comprehensive study of Vinyl Chloride production and related Vinyl Chloride production cost, covering three key aspects: a complete description of the Vinyl Chloride production process examined; an in-depth analysis of the related Vinyl Chloride plant capital cost (Capex); and an evaluation of the respective Vinyl Chloride plant operating costs (Opex).
The Vinyl Chloride 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 Vinyl Chloride 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 Vinyl Chloride 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 four major sections: (1) Direct Chlorination; (2) Oxychlorination; (3) EDC Cracking; and (4) Purification.
Direct Chlorination. Ethylene is chlorinated to produce EDC. The direct chlorination reaction is carried out in liquid phase, using EDC itself as the solvent. Typical conditions are 1 - 2.5 bar at about 100 °C. The reaction is conducted with a slight excess of ethylene, leading to a conversion of almost 100% and selectivity higher than 99%.
Oxychlorination. Hydrogen chloride (HCl) is reacted with ethylene and oxygen, yielding ethylene dichloride (EDC) and water. Oxychlorination is conducted above 200 °C. High conversion and selectivity are obtained with metallic chlorides catalysts. The EDC obtained is partially condensed and compressed before it is fed to a series of columns for purification. High-boiling and low-boiling compounds are recovered and converted to CO2, water and HCl, which is recycled to reaction.
EDC Cracking. EDC from Direct Chlorination and Oxychlorination is preheated, vaporized and thermally cracked yielding Vinyl Chloride Monomer (VCM), HCl and unreacted EDC. 60% conversion of EDC is typical, with selectivity to VCM greater than 96%.
Purification. The VCM obtained is partially condensed before it is fed to a series of columns, where HCl, EDC, VCM and impurities are separated. Hydrogen Chloride is recovered and recycled to oxychlorination. Unconverted EDC is returned to EDC purification, while VCM Product, presenting acidity content below 0.1 ppm, is stored.
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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 Vinyl Chloride 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 Vinyl Chloride 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 Vinyl Chloride 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 Vinyl Chloride 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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