Commodity Production Costs Report
PG Ethylene from Ethanol (Similar to Dow Chemical Process)
Ethylene Operating Costs & Plant Construction Costs
This study concerns Green Polymer Grade (PG) Ethylene production in the United States. The technology examined in this report is similar to the one developed by Dow Chemical. In this process, a selective oxidation reactor is used in the purification step to remove CO and hydrogen from the process.
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): ?
Product
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.
Raw Material
Ethanol. Ethanol, or ethyl alcohol, is a volatile, flammable, and colorless liquid (pure form). It is miscible in all proportions with water, ether, acetone, benzene, and some other organic solvents. Ethanol has been produced by the fermentation of carbohydrates for thousands of years. In the 1930s, low oil prices enabled the production of industrial ethanol through direct and indirect hydration of petroleum-derived ethylene. The rising cost of crude petroleum has prompted research into the industrial manufacture of ethanol from biomass sources. Ethanol from biomass can be produced by the fermentation of starch (from corn), sugar (from sugarcane) or waste lignocellulosic biomass (such as corn stover or switch grass). The process varies depending on the feedstock used. Due to governments’ programs and technology advances, biomass has become the lowest cost raw material for ethanol production. Currently, ethanol is almost exclusively obtained from biomass and has become a renewable-based chemical. Global concerns about sustainability and global warming have inspired research into the use of renewable ethanol for ethylene manufacture, substituting petroleum-derived ethylene.
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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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Other Related Production Cost Reports
Ethanol and Sugar Production from Sugarcane
This report presents a techno-economic study of hydrous Ethanol and raw sugar production from sugarcane using a typical process in Brazil. In this process, part of the sugarcane juice is used in the production of raw sugar and part is fermented to produce hydrous Ethanol. The sugarcane bagasse is burned for electricity generation.
Details: 150 kta Brazil-based plant | Q3 2024 | 107 pages | Issue E | From $799 USD
Homopolymer HDPE from Ethylene (Similar to MarTECH Loop Slurry)
This report presents the economics of High Density Polyethylene (HDPE) production from polymer grade (PG) ethylene in the United States, using a slurry loop process similar to Chevron Phillips MarTECH and INEOS INNOVENE S. In this process, the monomers are polymerized in a single loop reactor.
Details: 450 kta United States-based plant | Q3 2024 | 107 pages | Issue F | From $799 USD
Propylene Production from Ethylene and Butenes
This report presents the economics of Polymer Grade (PG) Propylene production from ethylene and raffinate-2. The process under analysis consists in a metathesis process similar to Lummus Technology's Olefins Conversion Technology (OCT). The economic analysis performed assumes a plant located in the United States.
Details: 350 kta United States-based plant | Q3 2024 | 107 pages | Issue A | From $799 USD
Ethanol Production from Corn Dry Milling
This study presents the economics of hydrous Ethanol production from corn in the United States using a typical dry milling process. Initially, corn is ground, slurried with water and then submitted to enzymatic hydrolysis, which convert starch to glucose. Next, the glucose is fermented to Ethanol by yeasts, yielding Hydrous Ethanol.
Details: 300 kta United States-based plant | Q3 2024 | 107 pages | Issue C | From $799 USD
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