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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  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 2021

1
1-Butene Production from Ethylene Learn More

This study presents the costs associated with the construction of an industrial plant producing 1-Butene from ethylene in the United States. This study analyzes a process similar to the Axens/SABIC AlphaButol technology. In the process under analysis, ethylene is dimerized into butenes with high selectivity for 1-Butene. Gasoline (C6+ stream) is generated as by-product.

Details: 50 kta United States-based plant   |   Q1 2019   |   108 pages   |   See Full Abstract

The cost analyses presented in this report target a 50 kta (kilometric tons per annun) United States-based plant.

2
1-Hexene Production from Ethylene Learn More

This report presents the economics of an industrial process for 1-Hexene production from ethylene, assuming a trimerization process similar to the one owned by Chevron Philips. The economic analysis is based on a plant operating in the United States.

Details: 200 kta United States-based plant   |   Q2 2019   |   108 pages   |   See Full Abstract

The cost analyses presented in this report target a 200 kta (kilometric tons per annun) United States-based plant.

3
Acetic Anhydride Production from Acetic Acid Learn More

This report presents the economics of Acetic Anhydride production from acetic acid in the United States via a ketene process. In the process, acetic acid is first dehydrated to ketene using triethylphosphate as catalyst in a cracking furnace. Ketene reacts with acetic acid in a series of scrubbers, producing Acetic Anhydride.

Details: 120 kta United States-based plant   |   Q4 2019   |   107 pages   |   See Full Abstract

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

4
Acrolein Production Learn More

This report presents the economics of Acrolein production from propylene in the United States, via catalytic oxidation.

Details: 30 kta United States-based plant   |   Q2 2019   |   107 pages   |   See Full Abstract

The cost analyses presented in this report target a 30 kta (kilometric tons per annun) United States-based plant.

5
Acrylic Acid Production from 3-Hydroxypropionic Acid Learn More

This report presents the economics of Acrylic Acid production from 3-hydroxypropionic acid (3-HP). 3-HP is submitted to a dehydration reaction to generate Glacial Acrylic Acid. The reaction is carried out in vapor phase in a reactor column. The economic analysis approaches a plant located in the United States.

Details: 150 kta United States-based plant   |   Q1 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.

6
Activated Carbon Production from Coconut Shell (Chemical Activation) Learn More

This study approaches an economic analysis of a typical chemical activation process for Powdered Activated Carbon production from coconut shell in the United States. Phosphoric acid is used as chemical activation reagent. Activation is carried out concomitantly with carbonization, in a rotary kiln.

Details: 20 kta United States-based plant   |   Q3 2018   |   108 pages   |   See Full Abstract

The cost analyses presented in this report target a 20 kta (kilometric tons per annun) United States-based plant.

7
Activated Carbon Production from Coconut Shell (Steam Activation) Learn More

This report presents the economics of a typical steam activation process for Powdered Activated Carbon production from coconut shell in the United States. In the process examined, the coconut shells are crushed and then carbonized into a charcoal, which is activated by steam at high temperatures. The Activated Carbon is ground into powder of specified mesh size.

Details: 15 kta United States-based plant   |   Q3 2018   |   108 pages   |   See Full Abstract

The cost analyses presented in this report target a 15 kta (kilometric tons per annun) United States-based plant.

8
Aluminum Hydroxide from Aluminum Sulfate and Soda Ash Learn More

This report presents the economics of a typical Aluminum Hydroxide Gel production process from aluminum sulfate and soda ash in the United States. In the process, soda ash and aluminum sulfate are dissolved in water and undergo a neutralization reaction to produce the aluminum hydroxide gel.

Details: 2 kta United States-based plant   |   Q1 2019   |   108 pages   |   See Full Abstract

The cost analyses presented in this report target a 2 kta (kilometric tons per annun) United States-based plant.

9
Ammonium Nitrate Porous Prills Production Learn More

In this study, the production costs of Ammonium Nitrate porous prills (AN-PP) are reviewed. The process examined is a typical vacuum neutralization process using ammonia and nitric acid for ammonium nitrate production. It is then evaporated and transformed into AN-PP. The economic analysis presented assumes a plant constructed in the United States.

Details: 400 kta United States-based plant   |   Q1 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.

10
Benzene from Toluene (Selective Toluene Disproportionation) Learn More

It presents the economics of a selective toluene disproportionation process (STDP) for Benzene production in the United States. In the STDP, toluene is converted into benzene and xylenes (mainly, p-xylene). The reaction is carried out with a zeolitic catalyst, in a hydrogen atmosphere to minimize coke formation and side reactions.

Details: 250 kta United States-based plant   |   Q2 2017   |   109 pages   |   See Full Abstract

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

11
Butadiene from Crude C4s (NMP Extraction) Learn More

This report analyses the economics of 1,3-Butadiene production from a crude C4s stream in the United States using an extraction process that uses N-methyl-2-pyrrolidinone (NMP) similar to BASF NMP. The extraction is conducted in counter-current in two steps. Raffinate-1 is generated as by-product in the process.

Details: 200 kta United States-based plant   |   Q4 2019   |   108 pages   |   See Full Abstract

The cost analyses presented in this report target a 200 kta (kilometric tons per annun) United States-based plant.

12
Chlorine Dioxide Production from Chlorine Learn More

This study presents the costs associated with the construction of a plant for Chlorine Dioxide production from chlorine in the United States. Initially, sodium chlorate is produced from caustic soda and hydrochloric acid solution via electrolysis. Hydrogen and chlorine are reacted in a furnace to form the pure hydrogen chloride. The sodium chlorate formed is then reduced with the hydrogen chloride to chlorine dioxide.

Details: 10 kta United States-based plant   |   Q2 2018   |   111 pages   |   See Full Abstract

The cost analyses presented in this report target a 10 kta (kilometric tons per annun) United States-based plant.

13
Emulsion Styrene Butadiene Rubber Production Learn More

This report presents the economics of SBR production starting from butadiene and styrene. The analysis encompasses a plant located in the United States, employing a typical cold emulsion process for generating a non-oil extended, non-staining grade of emulsion SBR (similar to 1502). In this process, an emulsion comprising water, styrene and butadiene is polymerized into a latex, which is then coagulated to form the SBR.

Details: 140 kta United States-based plant   |   Q1 2019   |   109 pages   |   See Full Abstract

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

14
Epichlorohydrin from Propylene (Allyl Alcohol Intermediate) Learn More

This study presents a techno-economic analysis of Epichlorohydrin production from propylene and chlorine in the United States. In this process, propylene is subjected to an acetoxylation reaction, followed by hydrolysis, generating allyl alcohol, which is then chlorinated, yielding glycerol dichlorohydrins. Finally, the glycerol dichlorohydrins generated are reacted with calcium hydroxide, yielding Epichlorohydrin.

Details: 110 kta United States-based plant   |   Q4 2019   |   111 pages   |   See Full Abstract

The cost analyses presented in this report target a 110 kta (kilometric tons per annun) United States-based plant.

15
Ethyl Acetate Production from Ethylene and Acetic Acid Learn More

This report examines the economics of Ethyl Acetate production from ethylene and acetic acid in the United States. The process examined is similar to the BP’s AVADA (AdVanced Acetates by Direct Addition of acetic acid to ethylene) technology.

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.

16
Gaseous Oxygen from Air (Cryogenic Process) Learn More

This study provides a techno-economic analysis of a typical cryogenic distillation process for Oxygen production using atmospheric air as the starting material. Oxygen main product and nitrogen by-product are produced as high pressurized gases. The economic analysis presented assumes a plant located in the United States.

Details: 800 MM Nm3a United States-based plant   |   Q1 2019   |   108 pages   |   See Full Abstract

The cost analyses presented in this report target a 800 MM Nm3a (kilometric tons per annun) United States-based plant.

17
Homopolymer HDPE from Ethylene (Similar to UNIPOL) Learn More

This report analyses the economics of High Density Polyethylene (HDPE) production from polymer grade (PG) ethylene in the United States. The process examined in this report is similar to Univation UNIPOL and INEOS INNOVENE G. In this process, ethylene is polymerized in the gas-phase in a reaction loop consisting of a fluidized-bed reactor, a compressor and a heat exchanger.

Details: 450 kta United States-based plant   |   Q2 2019   |   107 pages   |   See Full Abstract

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

18
Hydroxypropyl Methyl Cellulose Production Learn More

This report presents a feasibility analysis of Hydroxypropyl Methyl Cellulose (HPMC) production starting from cellulose, methyl chloride and propylene oxide. In this process, cellulose is alkalized with caustic soda and etherified first with propylene oxide and then with methyl chloride (dissolved in dimethyl ether), before passing through an etherification reaction. The plant is assumed to be located in the United States.

Details: 12 kta United States-based plant   |   Q2 2018   |   109 pages   |   See Full Abstract

The cost analyses presented in this report target a 12 kta (kilometric tons per annun) United States-based plant.

19
Impact PP from Propylene and Ethylene (Gas-Phase FBRs) Learn More

This report presents the economics of Polypropylene (PP) Impact Copolymer production from polymer grade (PG) propylene and ethylene in the United States. The process examined in this report is similar to Grace UNIPOL process. This process occurs in fluidized-bed reactors (FBRs) connected in series.

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.

20
Impact PP from Propylene and Ethylene (Horizontal Agitated Reactors) Learn More

This study presents the economics of Polypropylene (PP) Impact Copolymer production from polymer grade (PG) propylene and ethylene in the United States. This process is similar to INEOS INNOVENE and JPP HORIZONE processes. The reaction occurs in horizontal agitated reactors connected in series.

Details: 350 kta United States-based plant   |   Q2 2019   |   109 pages   |   See Full Abstract

The cost analyses presented in this report target a 350 kta (kilometric tons per annun) United States-based plant.

21
Impact PP from Propylene and Ethylene (Vertical Stirred-Bed Reactors) Learn More

This report examines the costs related to Polypropylene (PP) Impact Copolymer production from polymer grade (PG) propylene and ethylene in the United States. The process examined in this report is similar to Lummus Technology's Novolen process. This process occurs in vertical fluidized-bed reactors connected in series.

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.

22
Isopropyl Alcohol Production from PG Propylene Learn More

This report approaches the economics of Isopropyl Alcohol production from Polymer Grade (PG) Propylene. This study is based on a plant located in the United States. Isopropyl Alcohol is obtained via a typical direct propylene hydration process which is carried out in the vapour phase using phosphoric acid on silica as catalyst.

Details: 200 kta United States-based plant   |   Q2 2019   |   108 pages   |   See Full Abstract

The cost analyses presented in this report target a 200 kta (kilometric tons per annun) United States-based plant.

23
Methional Production from Acrolein and Methyl Mercaptan Learn More

This report presents the economics of Methional production from acrolein and methyl mercaptan in the United States, via a typical reaction in the presence of triethanolamine.

Details: 40 kta United States-based plant   |   Q2 2019   |   109 pages   |   See Full Abstract

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

24
Nitrobenzene Production from Benzene (Modular Tubular Reactor) Learn More

This report presents the economics of Nitrobenzene production from benzene and nitric acid in the United States. The process examined in this report is similar to Chematur's process, in which a tubular reactor is used.

Details: 480 kta United States-based plant   |   Q2 2019   |   109 pages   |   See Full Abstract

The cost analyses presented in this report target a 480 kta (kilometric tons per annun) United States-based plant.

25
Polyoxymethylene from Formaldehyde and Acetic Anhydride Learn More

In this report, it is assessed the production of Polyoxymethylene (POM), also called Polyacetal Resin. The economic analysis concerns Polyoxymethylene production from acetic anhydride and formaldehyde in the United States, assuming a process similar to the one owned by Dupont. Formaldehyde is initially concentrated and then polymerized in an inert cyclohexane medium. To enhance thermal stability, hydroxyl end groups are reacted with acetic anhydride.

Details: 110 kta United States-based plant   |   Q2 2017   |   109 pages   |   See Full Abstract

The cost analyses presented in this report target a 110 kta (kilometric tons per annun) United States-based plant.

26
Polypropylene Carbonate Production Learn More

This report provides the economics of Polypropylene Carbonate (PPC) production from propylene oxide and carbon dioxide in the United States using a process based on patents issued to SK Energy. In this process, the polymerization occurs in full-liquid phase and under pressure.

Details: 20 kta United States-based plant   |   Q2 2019   |   109 pages   |   See Full Abstract

The cost analyses presented in this report target a 20 kta (kilometric tons per annun) United States-based plant.

27
Polypropylene Nonwoven Production Learn More

This report presents the economics of Nonwoven production from polypropylene via spunbond technology. The economic analysis performed assumes a plant located in the United States.

Details: 10 kta United States-based plant   |   Q2 2019   |   107 pages   |   See Full Abstract

The cost analyses presented in this report target a 10 kta (kilometric tons per annun) United States-based plant.

28
PP Random Copolymer from Propylene and Ethylene (Gas-Phase FBRs) Learn More

It presents the economics of Polypropylene (PP) Random Copolymer production from polymer grade (PG) propylene and ethylene in the United States. The process examined in this report is similar to Grace UNIPOL process, which uses fluidized-bed reactors (FBRs).

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.

29
PP Random Copolymer from Propylene and Ethylene (Vertical Reactor) Learn More

This study presents the economics of Polypropylene (PP) Random Copolymer production from polymer grade (PG) propylene and ethylene in the United States. The process examined in this report is similar to Lummus Technoloy's Novolen, which uses a vertical stirred-bed reactors.

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.

30
Precipitated Silica Production Learn More

This report presents the economics of Precipitated Silica production from a sodium silicate solution and sulfuric acid in the United States. In the process, the sodium silicate solution is treated with sulfuric acid. The solution is precipitated, filtered, washed, and dried, producing Precipitated Silica.

Details: 50 kta United States-based plant   |   Q2 2019   |   108 pages   |   See Full Abstract

The cost analyses presented in this report target a 50 kta (kilometric tons per annun) United States-based plant.

31
Propionic Acid Production from Ethylene Learn More

This report presents the economic analysis of Propionic Acid production from ethylene. In this process, ethylene undergoes a hydroformylation reaction to produce propionaldehyde, which is oxidized to Propionic Acid product. The economic analysis presented is based on a plant constructed in the United States.

Details: 80 kta United States-based plant   |   Q2 2018   |   111 pages   |   See Full Abstract

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

32
Propylene Oxide Production from Propylene and Isobutane Learn More

This report examines the costs related to Propylene Oxide (PO) production from chemical grade (CG) propylene and isobutane in the United States. The process is similar to LyondellBasell process. In this process, isobutane is oxidized to produce t-butyl hydroperoxide, which reacts with propylene to produce PO.

Details: 450 kta United States-based plant   |   Q2 2017   |   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
Reformate from Naphtha (Semi-Regeneration) Learn More

This study reviews the costs associated with Reformate production from naphtha in the United States. The process under analysis is a semi-regeneration process similar to UOP RZ Platforming technology. In this process, naphtha is reformed through a series of reactions, in which paraffins are converted to aromatics. Hydrogen is generated as by-product.

Details: 800 kta United States-based plant   |   Q2 2017   |   109 pages   |   See Full Abstract

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

34
Styrene Production from Ethylbenzene Learn More

This report examines the costs related to Styrene production from ethylbenzene in the United States, via a typical adiabatic dehydrogenation process.

Details: 700 kta United States-based plant   |   Q1 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.

35
Trimethylolpropane Production Learn More

This report presents the economics of Trimethylolpropane (TMP) production from formaldehyde and n-butyraldehyde, assuming a plant located in the United States. In the process analyzed, formaldehyde and n-butyraldehyde go through an aldol condensation and a cross-Cannizaro reaction to form Trimethylolpropane, using 2,2-bis(hydroxymethyl)butanal as intermediate.

Details: 20 kta United States-based plant   |   Q2 2018   |   109 pages   |   See Full Abstract

The cost analyses presented in this report target a 20 kta (kilometric tons per annun) United States-based plant.

36
Weak Nitric Acid from Ammonia (Medium Pressure Process) Learn More

This report analyzes the economics of Nitric Acid production from ammonia via a typical Medium Pressure process in the United States. In this process, ammonia is initially oxidized to nitric oxide. Then, nitric oxide is oxidized to form nitrogen dioxide, and absorbed (at the same pressure) by water producing 65 wt% Nitric Acid solution as the final product.

Details: 250 kta United States-based plant   |   Q1 2019   |   108 pages   |   See Full Abstract

The cost analyses presented in this report target a 250 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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