Commodity Production Costs Report
Butadiene from Crude C4s (NMP Extraction)
Butadiene Operating Costs & Plant Construction Costs
This report analyses the economics of 1,3-Butadiene production from a crude C4s stream in the United States using an extraction process that uses N-methyl-2-pyrrolidinone (NMP) similar to BASF NMP. Raffinate-1 is generated as by-product in the process.
The report provides a comprehensive study of Butadiene production and related Butadiene production cost, covering three key aspects: a complete description of the Butadiene production process examined; an in-depth analysis of the related Butadiene plant capital cost (Capex); and an evaluation of the respective Butadiene plant operating costs (Opex).
The Butadiene 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 Butadiene 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 Butadiene 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) Extractive distillation; (2) Butadiene purification; and (3) Degasssing.
Extractive distillation. The C4 mixture containing butadiene, butenes, butanes and acetylenes is fed to the first extractive column, where recycled NMP solvent is added to the top section. The column overhead stream, which consists of butanes and butenes (raffinate-1) is sent to storage. The bottom stream containing butadiene, acetylenes and some butenes absorbed in NMP is fed to the top of the rectifier column. In this column, remaining butenes are separated in the top and recycled to the first extractive column while the bottoms containing mainly NMP is sent to the degassing section. Butadiene and some acetylenes are separated as a side stream of the rectifier column, which is fed to the second extractive column where recycled NMP solvent is added to the top in order to absorb the acetylenes, which are recovered in the bottoms and returned to the rectifier column. Crude butadiene is recovered in the overheads and sent to the butadiene purification section.
Butadiene purification. In this section, the crude butadiene stream is fed to the light ends column, where propyne is separated in the overheads. The bottoms of this column is sent to the heavy ends column, where 1,3-butadiene product is obtained in the overhead stream and heavy ends are separated in the bottoms.
Degassing. The NMP solvent from the bottoms of the rectifier column is stripped from light hydrocarbons which are separated as the distillate stream of the degassing column. These light hydrocarbons are fed to the rectifier column through a gas compressor. In the degassing column, the acetylenes are separated as a side stream and washed in a scrubber before being used as fuel whereas the NMP recovered in the bottom stream is recycled to the extractive distillation columns.
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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 Butadiene 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 Butadiene 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 Butadiene 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 Butadiene 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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