Commodity Production Costs Report
Butadiene Production from Butenes
Butadiene Operating Costs & Plant Construction Costs
This study presents the economics of 1,3-Butadiene (BD) production from mixed butenes in a plant assumed to be erected in the United States. In this process, which is similar to TPC/UOP Oxo-D, butenes are catalytically dehydrogenated to produce the Butadiene product. Raffinate is obtained as by-product.
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) Reaction; (2) Crude Butadiene Recovery; and (3) Purification.
Reaction. Butenes feed is vaporized and mixed with steam and compressed air before being fed to the reactor. Butenes react with oxygen, forming Butadiene and water. The excess heat generated by the exothermic reaction is used to generate part of the steam fed to the reactor. The reaction product comprises Butadiene, unreacted C4s (saturated and unsaturated), reaction side products (e.g. aldehydes), as well as steam, nitrogen, unreacted oxygen and carbon dioxide.
Crude Butadiene Recovery. The Butadiene-rich mixture from the reactor is quenched with water in a quench tower. Part of the water collected from the bottom of this column (comprising the quench water and condensate) is recycled to the top of the tower. The balance is used in the aldehyde separator downstream. The overhead Butadiene-rich gas is compressed and fed to the aldehyde separator, where it is scrubbed with water from quench tower bottoms. The aldehyde-free overheads is injected in the bottom of an absorber column, where a lean oil stream absorbs hydrocarbons from the gaseous reaction product. The oil/hydrocarbon mixture is further fed to a degasser column, where light compounds are separated as overhead gas. A crude Butadiene stream is obtained after the oil is separated from the C4 mixture in a stripper column.
Purification. The crude Butadiene, which still contains butane and butenes, is then subjected to extractive distillation in the presence of N-methylpyrrolidinone (NMP) used as solvent, yielding high purity Butadiene as the final product. Butane and butenes separated from the Butadiene are sold as raffinate by-product.
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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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