Commodity Production Costs Report

Ethylene Oxide Production from Ethylene (Air as Oxidizer)

Ethylene Oxide Operating Costs & Plant Construction Costs

550 kta United States-based plant | 107 Pages | Issue B | Q3 2024
Starting at $999 USD | See Report Editions Prices

This study examines Ethylene Oxide production in the United States. The process reviewed in this study is a direct oxidation technology using air instead of pure oxygen as the oxidizing agent.

The report provides a comprehensive study of Ethylene Oxide production and related Ethylene Oxide production cost, covering three key aspects: a complete description of the Ethylene Oxide production process examined; an in-depth analysis of the related Ethylene Oxide plant capital cost (Capex); and an evaluation of the respective Ethylene Oxide plant operating costs (Opex).

The Ethylene Oxide 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 Ethylene Oxide 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 Ethylene Oxide 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): ?

Ethylene Oxide Production Cost Report Process Schematic

The process under analysis comprises three major sections: (1) Oxidation; (2) Reagents Recovery; and (3) Products Separation.

Oxidation. Initially, fresh ethylene and compressed air are mixed with recycle gas (recovered downstream). The mixture is heated by heat exchange with reactor effluent, and fed into the multi-tubular catalytic reactor in which ethylene oxide (EO) is produced – Primary Reactor. Also, part of the ethylene is combusted, generating carbon dioxide and water.

Ethylene Oxide Recovery. The gaseous stream obtained from reactor outlet is sent to a cold water absorber – Primary Absorber – for the separation of light gases (mainly CO2, unreacted ethylene, and inert gases). The major part of the gaseous overhead stream is recycled to Primary Reactor. The other part is directed to a Purge System, where a reactor-absorber set in series, similar to Primary Reactor-Absorber, consumes unreacted ethylene, generating more EO, although decreasing its selectivity. A liquid solution, comprising EO dissolved in water, is obtained by combining all bottoms from the absorbers and is led to the third process section. Vent gas from the last absorber of Purge System is purged.

Products Separation. The EO/water stream from the absorbers is fed into the top of a stripper, where EO is steam stripped from water. The stripper bottoms – a water/ethylene glycol mixture – is routed to a column for recovering antifreeze grade ethylene glycol (MEG), sold as a by-product. The overhead gaseous stream, relatively concentrated in EO, is condensed and sent to EO Purification. This system consists of a two-column set. The first one removes light-ends, and crude EO is withdrawn from the bottom of this unit, while light gas is vented from the system. Then, the crude EO is fed into a final purification column for removal of water and heavy impurities. High-purity Ethylene Oxide obtained from column overhead is condensed and sent to storage. The bottoms stream is discharged as wastewater.

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  • Process Consumptions
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 80 Pages | 22 Tables | 9 Images

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Table of Contents


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  • Operating Cost Summary
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  • Operating Cost Details
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 90 Pages | 28 Tables | 13 Images

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Table of Contents


Features
  • Production Process Information
  • Process Consumptions
  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
  • Production Costs Datasheet
  • Plant Capital Cost Details
  • Operating Cost Details
  • Plant Cost Breakdowns
  • Plant Capacity Assessment
  • Process Flow Diagrams
  • Costs in Different Countries Add-on
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  • 107 Pages | 34 Tables | 22 Images
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Content Highlights

Plant Capital Cost Summary

Summary outlining the capital cost required for building the Ethylene Oxide 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 Ethylene Oxide 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 Ethylene Oxide 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 Ethylene Oxide 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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