Commodity Production Costs Report
Benzene Production from Light Oil
Benzene Operating Costs & Plant Construction Costs
This study shows a techno-economic analysis of Benzene production from light oil using a hydrodealkylation process similar to Lummus Litol technology. The light oil feedstock used is a product from coal coking process. A C6-C8 fraction is separated. Then, diolefins and styrene are hydrogenated. The effluent is finally converted to benzene by hydrodealkylation. The plant is assumed to be located in the United States.
The report provides a comprehensive study of Benzene production and related Benzene production cost, covering three key aspects: a complete description of the Benzene production process examined; an in-depth analysis of the related Benzene plant capital cost (Capex); and an evaluation of the respective Benzene plant operating costs (Opex).
The Benzene 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 Benzene 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 Benzene 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) Purification; (2) Reactions; and (3) Hydrogen Treatment.
Reactions. Initially, the coke-oven light oil is fractionated for the removal of C5- and C9+ fractions from the feedstock. The feed is then combined with recycled (unconverted) aromatics, forming a mixture that is vaporized with hot hydrogen and fed to a pre-treatment reactor. In the pre-treatment reactor, diolefins, cyclic diolefins, and styrene are selectively hydrogenated in the presence of a catalyst (cobalt molybdate on alumina), and a portion of thiophene and other sulfur compounds are converted to H2S. The hydrogenated effluent from the pre-treatment reactor is heated and subsequently fed to the fixed-bed reactors, where hydrocracking, dehydrogenation, and dealkylation reactions are carried out in the presence of chromia-alumina catalyst. Dealkylation reactions are exothermic, so the reaction temperature is controlled by recycling cold hydrogen between reactors.
Purification. The resulting effluent from the Dealkylation reactors is cooled and fed to a flash drum for the recovery of hydrogen. The liquid outlet is stabilized, clay treated, and then fractionated to obtain a finished benzene product.
Hydrogen Treatment. The gaseous stream from the flash drum is fed to the bottom of a multi-stage absorber column to remove residual hydrocarbons from the hydrogen-rich feed stream, avoiding the build-up of impurities in the process. The washed hydrogen-rich gas is mixed with a reformer-grade hydrogen makeup stream and then compressed and heated before being mixed with the feed mixture.
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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 Benzene 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 Benzene 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 Benzene 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 Benzene 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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