Commodity Production Costs Report
Acetylene Production from Calcium Carbide
Acetylene Operating Costs & Plant Construction Costs
This study presents the economics of Acetylene production from calcium carbide in the United States via wet process. In the process, calcium carbide reacts with water to form Acetylene. Hydrated lime is generated as by-product.
The report provides a comprehensive study of Acetylene production and related Acetylene production cost, covering three key aspects: a complete description of the Acetylene production process examined; an in-depth analysis of the related Acetylene plant capital cost (Capex); and an evaluation of the respective Acetylene plant operating costs (Opex).
The Acetylene 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 Acetylene 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 Acetylene plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Key reference(s): ?

The process under analysis comprises three major sections: (1) Acetylene generation; (2) Purification; and (3) Carbide Lime Recovery.
Acetylene generation. Initially, the calcium carbide is mixed with the water, which is present in large excess in the chamber (carbide-to-water principle) to help dissipate the heat of reaction between these two components generating the gaseous acetylene. A gaseous stream of acetylene and impurities, mainly sulfur and phosphorus compounds, exits from the generators top and proceeds to the purification section while a liquid stream of lime slurry exists from the bottom of the gasification tank as a by-product.
Purification. The acetylene formed first passes through a scrubbing tower, where the solids conveyed by the gas are removed. Subsequently, the Acetylene is fed to an absorption column where it flows countercurrent to a sulfuric acid solution, which acts as an oxidizing/neutralizing agent for the removal of impurities present in the Acetylene stream. The Acetylene is then passed through a caustic scrubber, where sulfur dioxide formed in the absorber column is removed by a caustic wash. Finally, the Acetylene is compressed, cooled and dried in silica gel beds before being sent directly to nearby facilities where it is consumed.
Carbide Lime Recovery. The carbide lime slurry coming from the Generator is fed to a decanter, in which a lime sludge is obtained and sent to a press filter to reduce the humidity to about 30%. The carbide lime cake is dried, crushed and sent to warehouses at the facility’s OSBL to be stored.
Report in PDF Format
Download & Explore Anytime
Access in Various Devices
Print & Read Comfortably
Share With Co-workers
Up-to-date Report
Professional report based on Q3 2024 economic data, ensuring timely evaluations.
Multiple Use Cases
Ideal for investment screening, feasibility studies, cost estimates, and research planning.
Proven Methodology
Developed using a consistent methodology honed over a decade, ensuring reliable cost analyses.
Report Editions
Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Acetylene 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 Acetylene 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 Acetylene 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 Acetylene 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
Other Acetylene Production Cost Reports

Acetylene Production from Coal and Lime
This analysis presents the costs associated with the construction and operation of a plant located in the United States for Acetylene production from coal using a typical calcium carbide process. In the process depicted, calcium oxide (lime) is reduced by carbon in an electric furnace, generating calcium carbide, which is then hydrolyzed to produce Acetylene and calcium hydroxide.
Details: 200 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $1,199 USD

Acetylene Production from Natural Gas (Electric Arc Process)
This feasibility study presents the economics of Acetylene production from natural gas using an electric arc process. In this process, a high-power electric arc furnace is employed to crack natural gas into olefinic compounds, including acetylene. The economic analysis also assumes a plant located in the United States.
Details: 50 kta United States-based plant | Q3 2024 | 107 pages | Issue C | From $999 USD

Acetylene Production from Naphtha
This study presents the economics of Acetylene production from naphtha using a partial combustion process. In this process, naphtha feedstock is cracked at high temperatures producing acetylene. The economic analysis developed is based on a plant constructed in Germany.
Details: 50 kta Germany-based plant | Q3 2024 | 107 pages | Issue E | From $799 USD
Could Not Find the Report You Need?
Obtain a Bespoke Report
Get a report targeting the process in which you are interested
See Offer Details
Understand Bespoke Reports and how you can easily order them
Check Editions & Pricing
Complete a brief form and see a quotation for your Bespoke Report
Other Related Production Cost Reports

Vinyl Acetate Production from Acetic Acid and Acetylene
This feasibility study examines the economics of a process producing Vinyl Acetate from acetic acid and acetylene. In the process examined, acetic acid and acetylene react in the vapor phase in the presence of a supported metal catalyst to produce vinyl acetate. The economic analysis performed is based on a plant constructed in the United States.
Details: 180 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $799 USD

Calcium Carbide from Limestone (Oxy-Thermal Process)
This study approaches the economics of Calcium Carbide production from limestone and coke in the United States via a oxy-thermal process. This process is based on the combustion of the carbonaceous material with oxygen in the presence of lime (generated by calcination of limestone raw material).
Details: 50 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $799 USD

Acetaldehyde Production from Acetylene (Vapor-Phase Hydration)
This report approaches the economics of an acetylene hydration process in the United States. In this study, hydration is carried out in vapor phase with steam over a solid catalyst.
Details: 70 kta United States-based plant | Q3 2024 | 107 pages | Issue D | From $799 USD

Calcium Carbide from Limestone (Electrothermic Process)
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 | Q3 2024 | 107 pages | Issue A | From $799 USD
+800 Reports Developed, Targeting +250 Commodities
Vast Report Library
858 independent and up-to-date reports examining embryonic and established production processes.
Free Sample Reports
Quickly understand the structure and depth of content of our professional reports.