Commodity Production Costs Report
Ethylene Production from Methane
Ethylene Operating Costs & Plant Construction Costs
This study presents an economic analysis of Ethylene production from methane in the United States using an oxidative coupling of methane (OCM) process. Carbon monoxide is also produced in the process and undergoes methanation, recovering methane.
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) Reactions; (2) CO2 Removal; and (3) Product Separation and Recovery.
Reactions. The methane recycle feed stream, containing CO and H2, coming from the demethanizer head is first heated. This methane stream is then sent to two-stage methanation reactors unit where CO is almost completely converted to methane in presence of hydrogen. The methane stream is mixed with oxygen, undergoing oxidative coupling (OCM) conversion to ethylene. Ethane is injected into the reaction system and is converted in ethylene utilizing the heat generated during methane conversion. Heat is recovered by generating high pressure steam.
CO2 Removal. The outlet stream from the reaction system is cooled and compressed in water quench system , to prevent further reactions and formation of undesirable by-products. Process gas stream is mixed with treated heat natural gas from Desulfurization. The mixed stream is treated in an Amine System to remove carbon dioxide using a Methyl diethanolamine-based unit. The resulting process gas is further treated with a caustic wash to complete remove any existing traces of CO2. The process gas leaving the caustic wash is then dried in a molecular sieve unit.
Product Separation and Recovery. The dried gas is fed to a cold box and cooled to cryogenic temperatures. Condensates from the chilling train are fed to separation columns. In the demethanizer, light ends and hydrogen are stripped off and recycled after treatment, while the bottom stream is fed to the deethanizer. The top stream is fed to an acetylene converter and then fractionated in the C2-splitter. Polymer grade ethylene is obtained as a side stream, and the bottoms stream, containing ethane, is recycled to methanator. The deethanizer bottom stream is fed to a depropanizer, which generates refinery grade propylene in the overheads and mixed C4s in the bottoms.
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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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