Production Cost Report
Petrochemicals

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Intratec provides the best-in-class professional studies examining production processes, with independent analysis of capital and operating costs. Our reports are focused on technologies for the production of +250 commodities, spanning the following sectors: Petrochemicals; Plastics & Polymers; Inorganic Chemicals; Fertilizers & Food; Oil, Gas & Derivatives; Renewables & Recyclabes.

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Our Reports Include

Key Process Information

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Assessment presenting relevant technical coefficients, accompanied by process description:

  • Raw materials consumption
  • Products generation
  • Labor requirements
  • Main process units description
  • Site infrastructure description
  • Block Flow Diagram

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Utilities Consumption

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Detailed assessment of utilities consumption:

  • Utility consumption rates per unit of product generated.
  • Share of each utility in the total utility costs.

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Capital Cost Analysis

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Analysis depicting all costs involved in starting a new industrial plant (capital investment):

  • Cost of construction (main process units, infrastructure, contingency)
  • Additional owner’s costs
  • Working capital
  • Plant commissioning and start-up

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Implementation Schedule

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Preliminary project implementation schedule, encompassing:

  • Basic Engineering
  • Detailed Engineering
  • Procurement
  • Construction
  • Plant Start-up

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Operating Cost Analysis

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Analysis depicting all costs surrounding the production of chemical:

  • Raw materials acquisition & utilities generation (variable manufacturing costs)
  • Labor wages, maintenance, operating charges, overhead, taxes and insurance (fixed manufacturing costs).
  • Corporate overhead costs

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Capacity Analysis

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Analysis of process economics for alternative plant capacities:

  • Plant costs of construction
  • Working capital
  • Variable and fixed operating costs
  • Depreciation
  • Corporate overhead

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  36 Reports per Year (See Sample)

  Best-in-Class Reports

  • Covering several technologies for the production of commodities (e.g. Petrochemicals; Polymers; Inorganics; Fertilizers; Renewables)

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  • Download reports in this program as non-printable PDF files. Access your reports offline, anytime you want

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Each Report Includes:

Key Process Information

  • Raw Materials Consumption
  • Block Flow Diagram
  • Technology Readiness

Capital Cost Analysis

  • Costs of construction (process units, infrastructure, contingency)
  • Working capital, owners' costs, comissioning and start-up

Operating Cost Analysis

  • Fixed and variable costs
  • Overhead

Capacity Analysis

  • Capital and operating costs breakdown for different plant capacities

Pricing Basis

  • Main prices considered in the analysis (raw materials, by-products, utilities)

Utilities Consumption

  • Breakdown presenting utility consumption rates (steam, cooling water, electricity, etc.)

Implementation Schedule

  • Schedule including duration of major project phases

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Reports Released in 2020

1
ABS from Polybutadiene, Acrylonitrile and Styrene (Mass Process) Learn More

This report assesses the economics of an industrial plant in the United States for the production of Acrylonitrile Butadiene Styrene (ABS) via a mass polymerization process. Initially, butadiene rubber is ground in a mill and dissolved in acrylonitrile and styrene. The mixture is submitted to a two-step copolymerization in the presence of a solvent.

Details: 120 kta United States-based plant   |   Q2 2019   |   109 pages   |   See Full Abstract

The cost analyses presented in this report target a 120 kta (kilometric tons per annun) United States-based plant.

2
Acrylic Acid Production from Propylene Learn More

This report presents the economics of Ester-Grade Acrylic Acid (EAA) production from chemical grade (CG) propylene in a plant located in the United States. The process consists in a two stage vapor-phase oxidation of propylene, yieding Acrylic Acid, which is then purified to obtain the Ester-Grade product.

Details: 150 kta United States-based plant   |   Q2 2019   |   108 pages   |   See Full Abstract

The cost analyses presented in this report target a 150 kta (kilometric tons per annun) United States-based plant.

3
Bio-Acrylic Acid Production from Raw Sugar (Single-Step Process) Learn More

This report shows a feasibility study of bio-based Acrylic Acid production from glucose syrup in a plant assumed to be located in Germany. The process is based on the fermentation route of raw sugar, yielding Acrylic Acid, similar to the speculative process proposed by the Delft University of Technology.

Details: 150 kta Germany-based plant   |   Q4 2019   |   109 pages   |   See Full Abstract

The cost analyses presented in this report target a 150 kta (kilometric tons per annun) Germany-based plant.

4
Glacial Acrylic Acid from Crude Acrylic Acid (Crystallization) Learn More

This report presents the costs associated with the construction of an industrial plant, in the United States, for crude acrylic acid purification to produce Glacial Acrylic Acid. The purification process examined is based on crude acrylic acid crystallization.

Details: 140 kta United States-based plant   |   Q2 2019   |   108 pages   |   See Full Abstract

The cost analyses presented in this report target a 140 kta (kilometric tons per annun) United States-based plant.

5
Acrylic Acid Production from Natural Gas Learn More

This report presents the economics of Ester-Grade Acrylic Acid (EAA) production from natural gas in the United States. Initially, methane in the natural gas feed is cracked to acetylene which is reacted carbon monoxide generated by feed combustion, yielding Acrylic Acid.

Details: 150 kta United States-based plant   |   Q4 2019   |   109 pages   |   See Full Abstract

The cost analyses presented in this report target a 150 kta (kilometric tons per annun) United States-based plant.

6
Allyl Chloride Production Learn More

This report presents a techno-economic analysis of a typical chlorination process for Allyl Chloride production from chlorine and propylene considering a plant constructed in the United States.

Details: 100 kta United States-based plant   |   Q2 2019   |   109 pages   |   See Full Abstract

The cost analyses presented in this report target a 100 kta (kilometric tons per annun) United States-based plant.

7
Ammonia Production from Coal Learn More

This report examines the costs related to Ammonia production from coal in China. In this process, coal dries and undergoes pyrolysis, producing coke. It reacts with steam and oxygen yielding mainly carbon monoxide (CO), hydrogen and carbon dioxide (CO2). CO and water are shifted to CO2 and hydrogen, which is finally reacted with nitrogen to produce ammonia.

Details: 800 kta China-based plant   |   Q1 2018   |   109 pages   |   See Full Abstract

The cost analyses presented in this report target a 800 kta (kilometric tons per annun) China-based plant.

8
Benzene from Toluene (Hydrodealkylation with Xylenes Production) Learn More

This study presents the economic analysis for the construction of an industrial plant for Benzene production from toluene in the United States. This study reviews a toluene hydrodealkylation (THDA) technology similar to Houdry's Detol. In this process, toluene is converted over a fixed-bed catalyst into Benzene. Mixed Xylenes are generated as by-product.

Details: 250 kta United States-based plant   |   Q2 2019   |   109 pages   |   See Full Abstract

The cost analyses presented in this report target a 250 kta (kilometric tons per annun) United States-based plant.

9
Benzene Production from Heavy Aromatics Learn More

This report shows the costs associated with Benzene production from toluene and heavy aromatics in the United States using a typical transalkylation process. Toluene also undergoes disproportionation and hydrodealkylation to form Benzene.

Details: 250 kta United States-based plant   |   Q4 2019   |   109 pages   |   See Full Abstract

The cost analyses presented in this report target a 250 kta (kilometric tons per annun) United States-based plant.

10
Bio-Butanol Production from Corn Learn More

This report presents the economics of bio-based Butanol production from corn in the United States. The process under analysis is a conventional Acetone-Butanol-Ethanol (ABE) fermentation process. Initially, corn undergoes wet milling to separate starch, which is hydrolyzed in two steps. Glucose is fermented to produce butanol, acetone and ethanol.

Details: 90 kta United States-based plant   |   Q2 2019   |   111 pages   |   See Full Abstract

The cost analyses presented in this report target a 90 kta (kilometric tons per annun) United States-based plant.

11
Butanol Production from Ethanol Learn More

The report shows an economic analysis of the construction of an industrial plant in the United States for n-Butanol production. In the process reviewed ethanol is dimerized into n-Butanol via the Guerbet reaction. This reaction is composed by dehydrogenation, aldol condensation and hydrogenation.

Details: 80 kta United States-based plant   |   Q4 2019   |   109 pages   |   See Full Abstract

The cost analyses presented in this report target a 80 kta (kilometric tons per annun) United States-based plant.

12
Calcium Carbide from Limestone (Electrothermic Process) Learn More

This report examines the costs related to Calcium Carbide production process from limestone and coke in the United States, using a typical electric arc furnace process. In the process, limestone is calcinated to lime, which reacts with coke in an electric arc furnace, producing calcium carbide.

Details: 80 kta United States-based plant   |   Q4 2019   |   108 pages   |   See Full Abstract

The cost analyses presented in this report target a 80 kta (kilometric tons per annun) United States-based plant.

13
Carbon Fiber Production from PAN fiber Learn More

This report provides a techno-economic analysis of a typical Carbon Fiber production process starting from polyacrylonitrile (PAN) fiber in the United States. In this process, PAN fiber is first stabilized. The stabilized PAN passes then through carbonization, surface treatment and sizing, before being winded.

Details: 2.50 kta United States-based plant   |   Q2 2019   |   108 pages   |   See Full Abstract

The cost analyses presented in this report target a 2.50 kta (kilometric tons per annun) United States-based plant.

14
Citric Acid Production Learn More

This report presents the economics of Citric Acid production from corn via a fermentation process. Initially, corn starch is hydrolyzed to fermentable sugars, which are bioconverted to Citric Acid via fermentation. The economic analysis is based on a plant constructed in the United States.

Details: 40 kta United States-based plant   |   Q4 2019   |   111 pages   |   See Full Abstract

The cost analyses presented in this report target a 40 kta (kilometric tons per annun) United States-based plant.

15
Cumene from Benzene and RG Propylene (Zeolite Catalyst) Learn More

This feasibility study reviews Cumene production from benzene and refinery grade (RG) propylene via an alkylation process, which is carried out using a zeolite catalyst. The economic assessment assumes a plant located in the United States.

Details: 300 kta United States-based plant   |   Q2 2019   |   109 pages   |   See Full Abstract

The cost analyses presented in this report target a 300 kta (kilometric tons per annun) United States-based plant.

16
Epichlorohydrin Production from Glycerol and Hydrogen Chloride Learn More

This study provides an economic analysis of Epichlorohydrin production from glycerol in the United States. Initially, glycerol is reacted with hydrogen chloride in a hydrochlorination reaction, generating dichlorohydrins (DCH). Then, the DCH is hydrolyzed by caustic soda, yielding epichlorohydrin (ECH).

Details: 100 kta United States-based plant   |   Q4 2019   |   109 pages   |   See Full Abstract

The cost analyses presented in this report target a 100 kta (kilometric tons per annun) United States-based plant.

17
Ethylene Dichloride from Ethylene and Chlorine (HTC with Stripping) Learn More

This report presents the economics of Ethylene Dichloride (EDC) production from ethylene and chlorine by direct chlorination in the United States. The process examined in this report is based on a liquid-phase high temperature chlorination (HTC) process, similar to the one developed by Vinnolit.

Details: 500 kta United States-based plant   |   Q1 2018   |   108 pages   |   See Full Abstract

The cost analyses presented in this report target a 500 kta (kilometric tons per annun) United States-based plant.

18
Ethyl Acetate Production from Ethanol and Acetic Acid Learn More

This study approaches the economics of Ethyl Acetate production from ethanol and acetic acid in the United States. In this process, Ethyl Acetate is produced by continuous esterification of acetic acid and ethanol.

Details: 100 kta United States-based plant   |   Q4 2019   |   109 pages   |   See Full Abstract

The cost analyses presented in this report target a 100 kta (kilometric tons per annun) United States-based plant.

19
Ethyl Acetate Production from Ethanol Learn More

This report presents a techno-economic analysis of Ethyl Acetate production from ethanol via process similar to the Johnson Matthey's Davy’s ethyl acetate technology. In this process, ethanol is dehydrogenated to acetaldehyde, which further reacts with ethanol to form Ethyl Acetate. The economic analysis provided assumes a plant located in the United States.

Details: 100 kta United States-based plant   |   Q1 2018   |   109 pages   |   See Full Abstract

The cost analyses presented in this report target a 100 kta (kilometric tons per annun) United States-based plant.

20
Ethyl Acetate Production from Acetaldehyde Learn More

This report examines the economics of Ethyl Acetate production from acetaldehyde in the United States via Tishchenko reaction, which refers to the dimerization of acetaldehyde in the presence of an alkoxide catalyst to form the ester.

Details: 100 kta United States-based plant   |   Q1 2018   |   108 pages   |   See Full Abstract

The cost analyses presented in this report target a 100 kta (kilometric tons per annun) United States-based plant.

21
Ethylene Production from Naphtha (Low Severity Steam Cracking) Learn More

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   |   Q2 2019   |   109 pages   |   See Full Abstract

The cost analyses presented in this report target a 800 kta (kilometric tons per annun) Germany-based plant.

22
PG Ethylene Production from Ethylene-Rich Gas Learn More

This report examines the costs related to Polymer Grade (PG) Ethylene production via purification of an ethylene-rich stream obtained from a typical ethane steam cracking plant. The economic analysis performed is based on a plant constructed in the United States.

Details: 400 kta United States-based plant   |   Q4 2019   |   109 pages   |   See Full Abstract

The cost analyses presented in this report target a 400 kta (kilometric tons per annun) United States-based plant.

23
Hydrogen Production from Natural Gas (Steam Reforming) Learn More

This report provides an economic analysis of Hydrogen production from natural gas in the United States using a steam reforming process. Initially, methane present in natural gas is cracked with steam generating syngas. Then, the carbon monoxide from syngas is reacted with steam, producing carbon dioxide and additional hydrogen.

Details: 1,000 MM Nm3a United States-based plant   |   Q4 2019   |   108 pages   |   See Full Abstract

The cost analyses presented in this report target a 1,000 MM Nm3a (kilometric tons per annun) United States-based plant.

24
Lactic Acid from Raw Sugar (Fermentation pH 6 with Acidification) Learn More

This study provides the economics of Lactic Acid production from raw sugar using a fermentation process in Germany. This process is similar to Corbion process, in which Lactic Acid is recovered by acidification and purified by the use of a solvent.

Details: 100 kta Germany-based plant   |   Q4 2019   |   109 pages   |   See Full Abstract

The cost analyses presented in this report target a 100 kta (kilometric tons per annun) Germany-based plant.

25
C4 to C16+ Linear Alpha Olefins Production Learn More

This study presents a techno-economic analysis of LAO production from ethylene in the United States. In this report, a process similar to INEOS process is analyzed, producing linear alpha-olefins ranging from C4 to C16+, mainly C6 to C10. Ethylene oligomerization is carried out in a reaction with triethylaluminum produced on site, increasing the chain of the alkyls bonded aluminum.

Details: 400 kta United States-based plant   |   Q2 2019   |   109 pages   |   See Full Abstract

The cost analyses presented in this report target a 400 kta (kilometric tons per annun) United States-based plant.

26
Methyl Methacrylate Production from Acetone, NH3 and Natural Gas Learn More

This report presents the economics of a process similar to Evonik Aveneer for Methyl Methacrylate (MMA) production from acetone and hydrogen cyanide (HCN) in the United States. Initially, HCN is produced from ammonia (NH3) and natural gas in an on-site unit. Then, acetone and methanol are used as raw materials for the production of MMA in six main steps, which are described in the report.

Details: 120 kta United States-based plant   |   Q2 2019   |   111 pages   |   See Full Abstract

The cost analyses presented in this report target a 120 kta (kilometric tons per annun) United States-based plant.

27
MTBE Production from Isobutylene Learn More

This report presents a techno-economic analysis of MTBE production from methanol and isobutylene in the Unites States. In this process, similar to UOP Ethermax process, a isobutylene-rich stream obtained from an isobutane dehydrogenation plant is etherified with methanol, producing MTBE.

Details: 700 kta United States-based plant   |   Q1 2018   |   109 pages   |   See Full Abstract

The cost analyses presented in this report target a 700 kta (kilometric tons per annun) United States-based plant.

28
Sodium Cyanide Solution Production Learn More

This study approaches the economics of Sodium Cyanide production from hydrogen cyanide and caustic soda. In this process, Sodium Cyanide is produced by reacting anhydrous hydrogen cyanide with a sodium hydroxide solution. The final product obtained is a Sodium Cyanide solution. The economic analysis provided assumes a complex located in the United States.

Details: 150 kta United States-based plant   |   Q1 2018   |   108 pages   |   See Full Abstract

The cost analyses presented in this report target a 150 kta (kilometric tons per annun) United States-based plant.

29
Nylon 6 Production from Caprolactam (Continuous Process) Learn More

This report presents the economics of Nylon 6 production from caprolactam in the United States. The process examined is a typical continuous ring-opening polymerization of caprolactam via the hydrolytic mechanism, carried out in two stages, similar to technologies developed/licensed by Thyssenkrupp (Uhde Inventa-Fischer) and Air Liquide (Lurgi Zimmer). An aminoacid is the intermediate for condensation.

Details: 100 kta United States-based plant   |   Q1 2018   |   108 pages   |   See Full Abstract

The cost analyses presented in this report target a 100 kta (kilometric tons per annun) United States-based plant.

30
Propylene Production from Vacuum Gas Oil (Catalytic Cracking) Learn More

This report presents the economics of Polymer Grade (PG) Propylene production from vacuum gas oil (VGO) in China. The portrayed process is similar to Sinopec Deep Catalytic Cracking (DCC) technology, in which VGO is converted to Propylene, generating propane, C4 fraction, C5+ naphtha and fuel oil as by-products.

Details: 400 kta China-based plant   |   Q4 2019   |   109 pages   |   See Full Abstract

The cost analyses presented in this report target a 400 kta (kilometric tons per annun) China-based plant.

31
PG Propylene Production from RG Propylene Learn More

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   |   Q2 2019   |   108 pages   |   See Full Abstract

The cost analyses presented in this report target a 400 kta (kilometric tons per annun) United States-based plant.

32
Propylene Oxide Production from Propylene and Hydrogen Peroxide Learn More

This report presents the economics of Propylene Oxide (PO) production from polymer grade (PG) propylene and hydrogen peroxide in the United States, similar to the hydrogen peroxide to propylene oxide (HPPO) process jointly developed by Evonik and Uhde.

Details: 450 kta United States-based plant   |   Q4 2019   |   109 pages   |   See Full Abstract

The cost analyses presented in this report target a 450 kta (kilometric tons per annun) United States-based plant.

33
Polyvinyl Chloride Production from VCM (Emulsion Polymerization) Learn More

It presents the economics of Polyvinyl Chloride (PVC) production from vinyl chloride monomer (VCM) in the United States. The process examined is a typical emulsion polymerization process in aqueous medium with emulsifiers.

Details: 100 kta United States-based plant   |   Q2 2019   |   108 pages   |   See Full Abstract

The cost analyses presented in this report target a 100 kta (kilometric tons per annun) United States-based plant.

34
Reformate Production from LPG Learn More

This report presents the economics of Reformate production from liquefied petroleum gas (LPG) in the United States, using a process similar to UOP Cyclar technology. In this process, reformate is passed through dehydrocyclodimerization, forming naphthenes. They are then dehydrogenated to the corresponding aromatics, forming reformate. Hydrogen is also generated as by-product

Details: 600 kta United States-based plant   |   Q4 2019   |   109 pages   |   See Full Abstract

The cost analyses presented in this report target a 600 kta (kilometric tons per annun) United States-based plant.

35
Reformate from Naphtha (Semi-Regeneration & Extra Sulfur Removal) Learn More

This feasibility study presents the economics of Reformate production from naphtha in the United States. This report examines a catalytic reforming process similar to Chevron Phillips Aromax technology. Hydrogen, crude C5s and heavy paraffins are generated as by-product.

Details: 700 kta United States-based plant   |   Q2 2019   |   109 pages   |   See Full Abstract

The cost analyses presented in this report target a 700 kta (kilometric tons per annun) United States-based plant.

36
Titanium Dioxide Production from Ilmenite Learn More

This report presents a feasibility study of Titanium Dioxide production from ilmenite in United States. In this process, ilmenite is digested with sulfuric acid forming titanyl sulfate, which is hydrolyzed to hydrated titanium dioxide. Then, it is calcinated to titanium dioxide.

Details: 120 kta United States-based plant   |   Q4 2019   |   108 pages   |   See Full Abstract

The cost analyses presented in this report target a 120 kta (kilometric tons per annun) United States-based plant.

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Intratec designed tailored subscription plans to attend corporate customers: each year customers get 36 best-in-class reports, for just a fraction of the cost! Our reports subscriptions are the best solution available in the market for corporate customers: while our reports cost typically between $1,599 and $2,999, subscribers get 36 reports for just $18,900, saving around 70%!

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