Commodity Production Costs Report
Butadiene Production from Ethanol
Butadiene Operating Costs & Plant Construction Costs
This report examines the costs related to 1,3-Butadiene (BD) production from hydrous ethanol in the United States. This process consists of a two-stage reaction process. First, ethanol is converted to acetaldehyde, which is then reacted with ethanol to produce 1,3-Butadiene. Raffinate 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 review comprises four main sections: (1) Acetaldehyde Conversion; (2) Butadiene Conversion; (3) Butadiene Recovery & Purification; (4) Ethanol and Acetaldehyde Recovery.
Acetaldehyde Conversion. Ethanol vapors are fed to a reactor where the dehydrogenation reaction occurs, catalyzed by a copper catalyst that produces acetaldehyde and hydrogen. The reactor effluent is then partially condensed. The non-condensed phase is scrubbed to recover the acetaldehyde from the gas phase containing hydrogen and light by-products. Part of the acetaldehyde-rich condensate is sent to purification steps, while the other fraction is used as a solvent in the butadiene scrubber.
Butadiene Conversion. Acetaldehyde is mixed with ethanol and fed to a second reactor where the condensation reaction occurs to produce Butadiene, with tantalum oxide as the catalyst. The products of this reaction are also partially condensed. Most of the Butadiene remains in the condensate, which is sent to downstream purification steps. The non-condensed phase passes through two scrubbers. The first one uses an ethanol-acetaldehyde mixture to recover the Butadiene, and the second scrubber uses water as solvent to recover the unreacted ethanol and acetaldehyde.
Butadiene Recovery & Purification. The solution containing the Butadiene produced is fed to a distillation column followed by a scrubber. The resulting Butadiene-rich stream is then sent to an extractive distillation system. Finally, a pre-purified Butadiene stream from the extractive distillation area is fed to a distillation column so as to recover a purified Butadiene product (with 99.6 wt% of purity).
Ethanol and Acetaldehyde Recovery. In this section the liquid streams from scrubbers and product recovery steps are fed to a sequence of three distillation columns to recover unreacted acetaldehyde and ethanol from by-products generated throughout the process due to side reactions.
Report in PDF Format
Download & Explore Anytime
Access in Various Devices
Print & Read Comfortably
Share With Co-workers
Up-to-date Report
Professional report based on Q3 2024 economic data, ensuring timely evaluations.
Multiple Use Cases
Ideal for investment screening, feasibility studies, cost estimates, and research planning.
Proven Methodology
Developed using a consistent methodology honed over a decade, ensuring reliable cost analyses.
Report Editions
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
Preview our Production Cost Reports
Other Butadiene Production Cost Reports
Butadiene Production from Butenes
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.
Details: 240 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $799 USD
Bio-Butadiene Production from Glucose (Aerobic Fermentation)
It presents the economics of bio-based 1,3-Butadiene (BD) production from glucose syrup in the United States using a direct aerobic fermentation process similar to the one proposed by Global Bioenergies.
Details: 165 kta United States-based plant | Q3 2024 | 107 pages | Issue D | From $799 USD
Bio-Butadiene Production from Raw Sugar (Aerobic Fermentation)
It presents the economics of bio-based 1,3-Butadiene (BD) production from raw sugar in Germany using a direct aerobic fermentation process similar to the one proposed by Global Bioenergies. Raw sugar is hydrolyzed into invert sugars, which are fermented to Butadiene.
Details: 165 kta Germany-based plant | Q3 2024 | 107 pages | Issue E | From $799 USD
Could Not Find the Report You Need?
Obtain a Bespoke Report
Get a report targeting the process in which you are interested
See Offer Details
Understand Bespoke Reports and how you can easily order them
Check Editions & Pricing
Complete a brief form and see a quotation for your Bespoke Report
Other Related Production Cost Reports
Ethanol and Sugar Production from Sugarcane
This report presents a techno-economic study of hydrous Ethanol and raw sugar production from sugarcane using a typical process in Brazil. In this process, part of the sugarcane juice is used in the production of raw sugar and part is fermented to produce hydrous Ethanol. The sugarcane bagasse is burned for electricity generation.
Details: 150 kta Brazil-based plant | Q3 2024 | 107 pages | Issue E | From $799 USD
Ethanol Production from Corn Dry Milling
This study presents the economics of hydrous Ethanol production from corn in the United States using a typical dry milling process. Initially, corn is ground, slurried with water and then submitted to enzymatic hydrolysis, which convert starch to glucose. Next, the glucose is fermented to Ethanol by yeasts, yielding Hydrous Ethanol.
Details: 300 kta United States-based plant | Q3 2024 | 107 pages | Issue C | From $799 USD
Emulsion Styrene Butadiene Rubber Production
This report presents the economics of SBR production starting from butadiene and styrene. The analysis encompasses a plant located in the United States, employing a typical cold emulsion process for generating a non-oil extended, non-staining grade of emulsion SBR (similar to 1502). In this process, an emulsion comprising water, styrene and butadiene is polymerized into a latex, which is then coagulated to form the SBR.
Details: 140 kta United States-based plant | Q3 2024 | 107 pages | Issue A | From $799 USD
Polychloroprene Production from Butadiene and Chlorine
This study provides an economic analysis of Polychloroprene production starting from butadiene and chlorine, based on a plant located in the United States. In the first step, butadiene is chlorinated, generating dichlorobutenes, which are subjected to an isomerization to convert them to 3,4-dichloro-1-butene. It is then dehydrochlorinated, forming chloroprene. Finally, chloroprene is polymerized to the respective rubber.
Details: 50 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $1,199 USD
+800 Reports Developed, Targeting +250 Commodities
Vast Report Library
858 independent and up-to-date reports examining embryonic and established production processes.
Free Sample Reports
Quickly understand the structure and depth of content of our professional reports.