Commodity Production Costs Report
Ethylene from PVC-Rich Mixed Plastic Waste
Ethylene Operating Costs & Plant Construction Costs
This report provides an economic analysis of Ethylene production via pyrolysis of mixed plastic waste rich in PVC in the United States. Initially, the chlorine content in the main stream is removed by reacting it with calcium carbonate. Then, the chlorine-depleted plastic stream is submitted to pyrolysis. The resulting pyrolysis gases are first sent to primary separation and finally distilled, yielding ethylene and other by-products.
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): ?
Products
Ethylene. Ethylene is known as a key building block for the petrochemical industry, being one of the largest-volume petrochemical produced worldwide. It is widely used as chemical intermediate in the production of several end products, including plastics, resins and fibers. Ethylene is largely produced by thermal cracking of petroleum-based feedstocks, in the presence of steam. It is stored in a liquid state under high pressure or at low temperatures. However, ethylene is, most of times, directly supplied to its consumers.
Propylene. Propylene, the main raw material consumed, is a colorless gas at room temperature. It is a low-boiling, flammable, and highly volatile gas, with molecular formula C3H6. Propylene reacts vigorously with oxidizing materials. It may be mildly irritating to the nose, throat, and respiratory tract; propylene has low acute toxicity from inhalation. PG Propylene has been mainly produced as ethylene manufacturing co-product (via steam cracking of paraffinic hydrocarbons) and by-product of petroleum refining (separation from refinery gas). Most recently, amid a tight propylene market, new and novel lower-cost chemical processes for on-purpose propylene production have emerged.
Raw Materials
Calcium Carbonate. Calcium Carbonate (CaCO3) is a compound commonly found as a white mineral (calcite) which occurs naturally in chalks, limestones and marbles. These rocks are classified as limestones, a general term used for a rock containing varying proportions of calcite and dolomite. The quality of calcium carbonate depends on some factors: purity, whiteness, homogeneity, and thickness.
Mixed Plastic Waste. Mixed Plastic Waste (70 wt% PE/PP, 6.5 wt% PVC, 13.5 wt% PS, 10 wt% rest) consists of a blend of polyolefins and other plastic types, primarily used in waste-to-energy processes or low-grade recycling. This mixture's varied composition poses challenges for traditional recycling, but it serves as feedstock for chemical recycling or alternative fuels, reducing the reliance on fossil resources.
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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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Calcium Carbonate Production from Lime and Soda Ash
This report presents the economics of Precipitated Calcium Carbonate (PCC) production from lime and sodium carbonate in the United States, via a conventional lime-soda process. In this process, calcium hydroxide is generated by treating lime with water. Then, calcium hydroxide reacts with soda ash. Besides PCC, an aqueous solution of sodium hydroxide is also obtained as product.
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Homopolymer HDPE from Ethylene (Similar to MarTECH Loop Slurry)
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