Commodity Production Costs Report
PG Ethylene Production from Ethylene-Rich Gas
Ethylene Operating Costs & Plant Construction Costs
This report examines the costs related to Polymer Grade (PG) Ethylene production via purification of an ethylene-rich stream obtained from a typical ethane steam cracking plant. The economic analysis performed is based on 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) C3+ Hydrocarbons Removal; (2) Acetylene Hydrogenation; (3) Light Ends Separation; and (4) Ethylene Fractionation.
C3+ Hydrocarbons Removal. Cracked gas, rich in ethylene, is fed to the deethanizer column. The column overhead vapor, consisting of C2 and lighter components, is sent to hydrogenation reactors. The stream composed of C3+ components obtained bottom is sold as fuel.
Acetylene Hydrogenation. The deethanizer overhead stream is compressed and fed to two hydrogenation reactors in series, for removing acetylene impurities, which are converted to ethylene and ethane. The hydrogenated stream, composed mainly of ethylene, ethane, methane and hydrogen, is cooled and partially condensed. The resulting liquid, comprising mainly impurities, stream is returned to the deethanizer, while the vapor is routed to the cold box downstream.
Light Ends Separation. The hydrogenation product stream is sent to a cold box, to separate light ends and hydrogen from ethylene and ethane. The hydrogen-rich gas is split: a portion is routed to a PSA unit for further purification and is returned to the hydrogenation reactors; the remainder is sold as by-product. The condensates from the chilling train are fed to the demethanizer column downstream, while light ends are used as fuel. The demethanizer strips off light ends and hydrogen from the ethylene/ethane stream and returns these components to the cold box.
Ethylene Fractionation. The C2 stream obtained as the demethanizer bottom is directed to the C2 splitter. In this column, while high purity ethylene is drawn from the column as a side stream. Ethane, from C2-splitter bottoms, is sent to the integrated unit.
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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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