Commodity Production Costs Report
Ethylene Production from Propane
Ethylene Operating Costs & Plant Construction Costs
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.
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) Cracking and Quenching; (2) Compression and Drying; and (3) Separation.
Cracking & Quenching. Propane is fed to furnaces in which it is cracked, forming Ethylene, propylene, and other by-products. The furnace outlet stream is routed to a quench, to prevent further reactions and formation of undesirable by-products. From a decanter downstream the quench tower, heavy hydrocarbons and water to waste treatment are removed. Cracked gas from the quench is sent to compression and separation.
Compression & Drying. The compression of the cracked gas is performed across 5 stages. After the third stage, carbon dioxide and sulfur are removed from cracked gas by caustic soda and water washes in a caustic scrubber. The compressed cracked gas is cooled and then dried in molecular sieves, so that most of the water is removed.
Separation. The dried cracked gas is fed to a cold box to remove hydrogen and light hydrocarbons, minimizing Ethylene losses. Condensates are fed to separation columns. In the demethanizer, methane is separated from the main stream that is fed to the deethanizer. The top of the deethanizer is fed to an acetylene converter and then fractionated in the C2-splitter. Ethylene is obtained as main product. The deethanizer bottom stream is fed to a depropanizer, which distillates C3 components. This stream is catalytically hydrotreated for impurities removal, and then fed to the C3-splitter. PG propylene is drawn from the column as a side stream. The Depropanizer bottom stream is separated into a crude C4 stream, recovered as column overhead product, and pyrolysis gasoline by-product. The crude C4 stream is condensed and fed to extraction columns, in order to separate raffinate-1. The crude butadiene stream is fed to the distillation columns so as to purify butadiene.
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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.
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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 n-Butane
This study presents an economic analysis of n-butane steam cracking for Polymer Grade Ethylene production in the United States. In this process, n-butane is thermally cracked in pyrolysis furnaces through the use of steam to obtain ethylene and other hydrocarbons. Polymer grade propylene, butadiene. Raffinate-1 and pygas are also generated as by-products.
Details: 900 kta United States-based plant | Q3 2024 | 107 pages | Issue E | From $799 USD
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