Vinyl Chloride Production from Acetylene
Vinyl Chloride Production Costs Report | Issue C | Q3 2024
Report Details |
280 kta United States-based plant | Q3 2024 | 107 pages |
This report presents a cost analysis of a 280 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 feasibility study reviews a typical hydrochlorination process for Vinyl Chloride production from acetylene. In this process, anhydrous hydrogen chloride is reacted in vapor phase with acetylene over a mercuric chloride catalyst producing Vinyl Chloride. The economic analysis presented is based on the construction of an industrial plant in the United States.
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 three major sections: (1) Reaction; (2) VCM Purification; and (3) Acetylene Recovery.
Reaction. Compressed acetylene is passed through dryers for removal of any residual moisture and then fed to guard beds to remove any contaminants that may damage catalyst activity. Purified acetylene is mixed with anhydrous hydrogen chloride. The gaseous raw materials are fed to a multi-tubular heat exchanger, in which tubes are packed with catalyst and a cooling fluid is fed to the shell to remove the heat generated by the reaction.
VCM Purification. The reaction effluent is twice scrubbed with water and caustic solution to remove any hydrogen chloride. A diluted hydrochloric acid is sent to hydrogen chloride recovery and wastewater is disposed. Gaseous effluent is recompressed, cooled and fed to a three-phase separator. The uncondensed light ends are transferred to the Acetylene Recovery.The organic liquid phase is transferred to a column for further purification. Vinyl Chloride crude product is recovered as the bottom stream. VCM crude product is fed to the final purification column, where purified VCM is recovered in the column overhead and stored.
Acetylene Recovery. Uncondensed light ends from the Dehydration Column are fed to an absorption column, in which acetylene is absorbed in liquid chlorinated hydrocarbons. Acetylene absorbed is recovered in a stripping column. The acetylene removed as overhead stream is recycled to reactor feed.
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Production Process Information
Process Consumptions
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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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