Acetylene Production from Coal and Lime

This report presents the economics of Acetylene production from coal via a typical calcium carbide process. The process examined is a typical calcium carbide process followed by a hydrolysis. In this process, calcium oxide (lime) is reduced by carbon in a electric furnace, generating calcium carbide. This intermediate is then hydrolyzed to produce Acetylene, the main product, and calcium hydroxide, a 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.