Vinyl Chloride Production from Ethylene and EDC
Vinyl Chloride Production Costs Report | Issue E | Q2 2024
Report Details |
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.
Report Abstract
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.
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) Oxychlorination; (2) EDC Cracking; and (3) Purification.
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.
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.
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.
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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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