Commodity Production Costs Report
Benzene Production from Naphtha
Benzene Operating Costs & Plant Construction Costs
This study provides the economics of Benzene production from naphtha in the United States using an integrated aromatics complex, which involves the co-production of p-Xylene. In this process, naphtha is reformed, and the reformate is separated into Benzene, xylenes and toluene, which undergoes disproportionation, forming the other two products.
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 four major sections: (1) Naphta Hydrotreatment & Reforming; (2) Aromatics Separation; (3) Toluene Disproportionation; (4) Paraxylene Recovery
Naphta Hydrotreatment & Reforming. Initially, the naphtha feedstock is treated with hydrogen under high temperature and pressure conditions to remove impurities that act as poison for the catalysts downstream. The treated naphtha is then sent to catalytic reforming, where paraffins and naphthenes are converted to aromatics. The product from reforming is then sent to the aromatics separation section.
Aromatics Separation. The reformate is fed to a reformate splitter, where a C7- fraction is obtained as the top product and a C8+ heavier fraction as the bottom product. The C7- fraction is fed to a sulfolane extraction unit for aromatics recovery. The aromatic extract is sent to a column to recover the Benzene as the top product. The bottom of this column is fed to a second column where toluene is separated as distillate, while the bottom stream is fed to the xylene splitter, where xylenes are separated as the top product from C9+ aromatics, that exit from the bottom. These heavy aromatics are fed to a fourth column, where a C9 fraction is produced as overhead and then mixed with the toluene stream to be sent to the toluene disproportionation section.
Toluene Disproportionation. The toluene and C9 aromatics mix is then fed to a reactor to be converted into xylenes and benzene via disproportionation reaction. The product from the disproportionation unit is then recycled to the benzene column.
Paraxylene Recovery. The mixed xylenes produced as the top product of the xylene splitter are fed to an adsorption unit, where paraxylene is separated and purified. The separated raffinate stream is fed to an isomerization step, where ortho- and metaxylene, as well as ethylbenzene, are isomerized into paraxylene. The reactors effluent is sent to the deheptanizer, where C7 and lighter components are removed as the overhead product, while a mixed xylenes stream exits from the bottom and returns to the xylene splitter.
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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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