Commodity Production Costs Report
PG Ethylene from Ethanol (Similar to Scientific Design Process)
Ethylene Operating Costs & Plant Construction Costs
This report approaches the economics of Green Polymer Grade (PG) Ethylene production from hydrous ethanol using a dehydration process similar to the process developed by Scientific Design. In this process, the reaction system is composed of only one reactor and one furnace. The study also assumes a plant constructed in the United States.
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 four major sections: (1) Reaction; (2) Compression, Caustic Washing, and Drying; (3) Steam Generation; and (4) Purification.
Reaction. The ethanol stream is vaporized and superheated through heat integration with the reactor effluent. The superheated ethanol vapors are then mixed with steam and fed to the dehydration reactor. Once in contact with the fixed catalyst bed, the ethanol dehydration reaction occurs and the temperature drops. The hot reactor effluent is first cooled by the heat integration with reactor feed and then transferred to a partial condenser, in which most of the water is condensed by means of cooling water and transferred to the aldehyde stripper.
Compression, caustic washing, and drying. After reaction, the crude ethylene stream is compressed before entering the caustic washing column, where impurities are removed with a caustic solution. Process water is also supplied to this column to avoid caustic entrainment along with the ethylene overhead stream, which is cooled by interchange with the ethylene product stream. Water separated in the compression and cooling stages is sent to the aldehyde stripper. Next, the gas stream is dehydrated in a molecular sieve unit.
Steam Generation. In this column, residual aldehydes are separated from condensed water. Aldehydes are recovered as the overheads vapor product and directed to the furnace to be used as fuel. A portion of the condensed water is discarded as wastewater, while the remainder is vaporized. The steam, also containing small amounts of unconverted ethanol, is heated by heat exchange with reactor effluent. The superheated steam is then fed in to the furnace for the last superheating step. The superheated steam is sent to the inlet of the reactor to be mixed with superheated ethanol.
Purification. The dehydrated stream is fed into the ethylene column, where heavy residues are removed. Next, carbon monoxide is removed in the stripper column. The two columns share a single condenser, which uses propylene refrigerant. The polymer grade ethylene (99.9 wt%) product is obtained in the bottoms of the stripper column and used to cool process streams in heat integrations.
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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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