Production Cost Report
ICC - Is Bespoken: 0
ICC - Main References: ?
ICC - Issue: E
ICC - Volume: 176
ICC - Report ID: 176-E
ICC - Report Location: United States
ICC - Is Popular: 0
ICC - Is Developed: 1
ICC - Title: Vinyl Chloride Production from Ethylene and EDC
ICC - Show Overview: 1
ICC - Report Location ID: 1
ICC - Plant Capacity Unit ID: 14
ICC - Volume Reports List: 176-A,176-B,176-C,176-D,176-F
ICC - Related Reports List: 181-B,235-A,235-B,172-B,181-A,172-A
ICC - Report Location Code: USA
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ICC - Prices: {"versions":{"1":{"1":"1199","2":"1199","3":"1199"},"2":{"1":"1999","2":"1999","3":"1999"},"3":{"1":"3399","2":"3399","3":"3399"}},"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/176-E.jpg
ICC - Process Overview Text: <h6>Product</h6> <p><b>Vinyl Chloride</b>. Vinyl chloride, or vinyl chloride monomer (VCM), is a major chemical commodity, with worldwide importance related to its industrial use as the precursor to PVC. VCM is also used in a wide variety of copolymers. Inherent flame-retardant properties, wide range of plasticized compounds, and low cost of polymers produced from vinyl chloride have made it in fact a major industrial chemical, manufactured in about fifty countries. First commercially produced by catalytic hydrochlorination of acetylene, vinyl chloride nowadays is largely produced through ethylene-based, balanced vinyl chloride process. VCM production routes development have been tightly connected to the availability of key raw materials, particularly ethylene and chlorine, along with concerns related to energy efficiency, environmental impact, safety, and process reliability. Most of the existing VCM plants are actually integrated to EDC plants, where direct chlorination and oxychlorination processes are employed in parallel for EDC production.</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>Ethylene Dichloride</b>. Ethylene dichloride (also known as 1,2-Dichloroethane, EDC and DCE) is by far the most produced chlorinated hydrocarbon. It is mainly employed in the production of vinyl chloride monomer (VCM), starting material for the production of polyvinyl chloride (PVC). Virtually all commercial production of EDC is based on the chlorination of ethylene, where chlorine or hydrogen chloride with oxygen may be used as chlorinating agent. Chlorination based on chlorine is referred to as direct chlorination, and as oxychlorination when based on hydrogen chloride. Actually, while most of the EDC plants are integrated to vinyl chloride monomer plants, both processes are employed in parallel for EDC production, in such a way that the hydrogen chloride by-product from VCM production is consumed in the oxychlorination process.</p>
ICC - Process Schematic Image: //cdn.intratec.us/images/icc/process-schematics/176-E.jpg
ICC - Process Schematic Text: <p>The process under analysis comprises three major sections: (1) Oxychlorination; (2) EDC Cracking; and (3) Purification.</p><p>Oxychlorination. Fresh and recycled ethylene, oxygen and hydrogen chloride (recovered downstream), 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. EDC with a purity of 99.9 wt% is obtained and sent to the EDC Cracking section. The liquid and gaseous by-products generated from side reactions, are subjected to a catalytic oxidation treatment converting the by-products to CO2, water and HCl. The HCl is recovered and used in the oxychlorination reaction.</p><p>EDC Cracking. Fresh EDC along with EDC from Oxychlorination is preheated, vaporized and thermally cracked in a pyrolysis furnace heated by fuel combustion. The cracking reaction is endothermic and generates VCM, HCl, by-products of various chemical structures and coke. The furnace operates at temperatures above 480 °C and pressure of about 16 bar. Cracking rates of up to 60% and a selectivity to VCM greater than 96% are obtained.</p><p>Purification. The output from the pyrolysis furnace 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 columns of the oxychlorination section, while monomer grade Vinyl Chloride, presenting acidity content below 0.1 ppm, is obtained as the final product and sent to storage tanks located outside battery limits.</p>
ICC - Short Description: This report presents the production cost of Vinyl Chloride from ethylene and ethylene dichloride (EDC) in the United States. The process examined combines two process. First, Vinyl Chloride is produced via thermal cracking of EDC, which generates hydrogen chloride (HCl). It is then used as raw material with ethylene in the EDC production via oxychlorination.
ICC - Main Product: Vinyl Chloride
ICC - Plant Capacity: 500.00
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Vinyl Chloride Production from Ethylene and EDC

Vinyl Chloride Production Costs Report | Issue E | Q2 2024

Production Cost Report

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500 kta United States-based plant   |   Q2 2024   |   107 pages   |   Delivered in PDF

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.

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Production Process Information

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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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This report presents the economics of Vinyl Chloride production from ethylene dichloride (EDC) in the United States using a typical thermal cracking process. In the process under analysis, EDC is thermally cracked to produce Vinyl Chloride, also generating hydrogen chloride as a by-product.

Details: 500 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue A   From $799 USD

The cost analyses presented in this report target a 500 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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This study reviews the costs associated with Vinyl Chloride production directly from ethane and chlorine. The process examined is an early stage process similar to that developed by European Vinyls Corporation, now owned by INEOS. The process is a direct ethane to vinyl chloride monomer route. The economic assessment assumes an industrial plant in the United States.

Details: 500 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue B   From $1,199 USD

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Vinyl Chloride Production from Acetylene

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.

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Vinyl Chloride from Ethylene and Chlorine (Balanced Process)

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”.

Details: 500 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue D   From $1,499 USD

The cost analyses presented in this report target a 500 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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This study approaches a detailed cost analysis of Vinyl Chloride (VCM) production from ethylene and chlorine as raw materials. Initially, ethylene is chlorinated to produce ethylene dichloride (EDC). Then, EDC is thermally cracked yielding VCM. The economic analysis presented assumes a plant located in the United States.

Details: 500 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue F   From $1,199 USD

The cost analyses presented in this report target a 500 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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