Commodity Production Costs Report

Ethylene from Ethanol (Similar to Chematur Process)

Ethylene Operating Costs & Plant Construction Costs

300 kta United States-based plant | 107 Pages | Issue J | Q3 2024
Starting at $799 USD | See Report Editions Prices

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): ?

Ethylene Production Cost Report Process Schematic

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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  • Production Process Information
  • Process Consumptions
  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
  • Production Costs Datasheet
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 80 Pages | 22 Tables | 9 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
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 90 Pages | 28 Tables | 13 Images

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Updated with Q3 2024 Data

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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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  • Updated with Q3 2024 Data
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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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