Commodity Production Costs Report
Ethylene Production from Ethane
Ethylene Operating Costs & Plant Construction Costs
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.
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 can be divided in three main parts: (1) Cracking & Quenching; (2) Compression & Drying; and (3) Separation.
Cracking & Quenching. Ethane and dilute steam are fed to furnaces in which, under high severity conditions, ethane is cracked forming ethylene and some by-products. The furnace outlet stream is subsequently fed to a water-based quench, to prevent further reactions and formation of undesirable by-products. From the quench tower the cracked gas is directed to compression and drying.
Compression & Drying. The compression of the cracked gas is performed across 5 stages. After the third stage of compression, carbon dioxide and sulfur are removed from the cracked gas by caustic soda and water washes in a caustic scrubber. After caustic wash, the cracked gas is fed to a fourth compression stage and then sent to the separation steps.
Separation. The product from fourth compression stage is fed into a column for removing C3+ hydrocarbons. The top product from this column, composed primarily of ethylene and ethane, is fed to the last compression stage (not shown in the diagram). The compressed gas is fed to an acetylene converter and then to a cold box for hydrogen and light hydrocarbons removal, ensuring that ethylene losses are minimal. At this point, the product from the chilling train is fed to two more separation columns. In the first column, methane is obtained from the top and further used in the cold box, while the bottom stream is fractionated in the C2-splitter. In this column, high-purity ethylene is drawn from the column as a side stream. Ethane, from C2-splitter bottom, is recycled to the cracking furnaces.
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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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