Commodity Production Costs Report
Ethylene from Ethanol (Similar to Chematur Process)
Ethylene Operating Costs & Plant Construction Costs
This report provides the economics of Green Polymer Grade (PG) Ethylene production from hydrous ethanol in the United States using a dehydration process examined in this report is similar to the processes developed by Chematur and Petron. In this process, the reaction is carried out multiple reactors in series and a single furnace.
The report provides a comprehensive study of Ethylene production and related Ethylene production cost, covering three key aspects: a complete description of the Ethylene production process examined; an in-depth analysis of the related Ethylene plant capital cost (Capex); and an evaluation of the respective Ethylene plant operating costs (Opex).
The Ethylene 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 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 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) Quenching, Compression, Caustic Washing, and Drying; and (3) Purification.
Reaction. Ethanol is vaporized, heated in a furnace and fed to the first reactor. During reaction, the temperature drops and the output stream must be re-heated before entering the next reactor. This is repeated until the fourth reactor, where ethanol reaches 99% of conversion. Next, the reactor product stream is cooled in a waste heat boiler, generating steam.
Quenching, compression, caustic washing, and drying. After reaction, the product stream has its water content reduced in a quench column. The ethylene stream leaves by the overheads and is compressed before entering the caustic washing column, where impurities are removed with a caustic solution. Process water is also supplied to this column to avoid caustic entrainment along with the ethylene overhead stream, which is cooled by interchange with the ethylene product stream. Water separated in the compression and cooling stages is recycled to the quench column. Next, the gas stream is dehydrated in a molecular sieve unit.
Purification. After cooling by interchange with the ethylene product, the dehydrated stream is fed into the ethylene column, where heavy residues are removed. Next, light impurities are removed in the stripper column. The two columns share a single condenser, which uses propylene refrigerant. The polymer grade ethylene (99.9 wt%) product is obtained in the bottoms of the stripper column and used to cool process streams in heat integrations.
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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 Ethylene 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 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 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 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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Other Ethylene Production Cost Reports
Ethylene Production from Ethane
This report presents the economics of Polymer Grade (PG) Ethylene production from ethane in the United States. In the process under analysis, ethane is thermally cracked in pyrolysis furnaces through the use of steam, yielding Ethylene. A hydrogen-rich gas is generated as by-product.
Details: 1200 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $799 USD
Ethylene Production from Ethane/Propane Mixture
This report presents the economics of Polymer Grade (PG) Ethylene production from ethane and propane in the United States. In the process under analysis, the mixture is submitted to a steam cracking process, yielding PG Ethylene. A hydrogen-rich gas and polymer grade propylene are generated as by-products,
Details: 1700 kta United States-based plant | Q3 2024 | 107 pages | Issue C | From $799 USD
Ethylene Production from Propane
This report presents the economics of Polymer Grade (PG) Ethlyene production from propane in the United States. In the study under analysis, propane is submitted through a steam cracking process, producing PG Ethylene. Pygas, a crude C4s stream, and PG propylene are generated as by-products.
Details: 1200 kta United States-based plant | Q3 2024 | 107 pages | Issue D | From $799 USD
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