Commodity Production Costs Report
Acetylene Production from Natural Gas (Partial Combustion Process)
Acetylene Operating Costs & Plant Construction Costs
This report presents the economics of Acetylene production from natural gas using a partial combustion process similar to that developed by BASF. In this process, methane from natural gas is cracked in high temperatures to acetylene and hydrogen. The economic analysis developed is based on a plant constructed in the United States.
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) Reaction; (2) Purification; and (3) Solvent recovery.
Reaction. Initially, the natural gas feed and oxygen are preheated and fed to a burner, which consists of a watercooled steel plate with several small combustion channels. The preheating reduces the consumption of oxygen and hydrocarbon within the burner. Approximately two-thirds of the methane is burned, while the remainder is cracked to Acetylene. The hot gas leaves the reaction chamber after a few milliseconds, at the optimum yield of acetylene, and is promptly cooled down with water (quench system).
Purification. Soot present in the cracked gas, formed in the reaction chamber, is partly removed from the gas by the water quench, with the remainder being removed by a recirculated water wash in a cooling column. The gaseous outlet is compressed and Acetylene is recovered by selective absorption into N-methylpyrrolidinone (NMP) solvent in the main scrubber. This column off-gas is a crude synthesis gas stream. The Acetylene solution is subsequently vacuum stripped to recover the gas, which is then scrubbed with acid and caustic solutions to attain the desired purity. The purified Acetylene is finally sent to consumers.
Solvent recovery. The NMP solution must be degassed in multiples steps at reducing pressures and increasing temperatures. NMP solvent is completely degassed and proper for reuse in the main scrubber. The remaining vapor stream, comprising mainly higher acetylenes, is used as fuel gas.
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Professional report based on Q3 2024 economic data, ensuring timely evaluations.
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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
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Other Acetylene Production Cost Reports
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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
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