Commodity Production Costs Report
MTBE Production from Butane
MTBE Operating Costs & Plant Construction Costs
This report presents a feasibility analysis of an on-purpose Methyl tert-Butyl Ether (MTBE) production plant from butane and methanol in the United States. Initially, n-butane is isomerized to isobutane, which is then subjected to a dehydrogenation, yielding isobutylene. In the final step, generated isobutylene and methanol react leading to the formation of MTBE. These steps are similar to Butamer, Oleflex and Ethermax processes in sequence.
The report provides a comprehensive study of MTBE production and related MTBE production cost, covering three key aspects: a complete description of the MTBE production process examined; an in-depth analysis of the related MTBE plant capital cost (Capex); and an evaluation of the respective MTBE plant operating costs (Opex).
The MTBE 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 MTBE 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 MTBE 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) Butane Isomerization; (2) Isobutane Dehydration; and (3) Isobutylene Etherification.
Butane Isomerization. Fresh n-butane, recycled isobutane, and a recovered stream from the Depropanizer downstream are fed to the Deisobutanizer Column. The overhead stream, rich in isobutane, is sent to the Dehydrogenation Preheaters, while the bottom stream containing heavier components is burned as fuel, and a side stream rich in butane is directed to the Isomerization Reactor. Hydrogen recovered from the Cold Box downstream is also fed to this reactor, in which butane is converted into isobutane, and sent to the Lights Removal area, where it is recovered to the Deisobutanizer Column, while a light-ends stream is obtained and burned as fuel.
Isobutane Dehydration. The Deisobutanizer overhead stream is fed to heaters to reach the reaction temperature, and then Dehydrogenation Reactors, where isobutane is converted into isobutylene. A Catalyst Regeneration Unit recovers and returns catalyst to the reactors. The outlet stream from the last reactor is compressed and routed to the Cold Box, where it is liquefied and sent to the Etherification Reactor, while a gaseous stream is routed to a PSA Unit to recover light-ends, burned as fuel, and hydrogen, sent to the Isomerization Reactor upstream.
Isobutylene Etherification. The liquid stream from the Cold Box is mixed with methanol and fed to the Etherification Reactor, where isobutylene is converted into MTBE. The reactor effluent is sent to the Catalytic Distillation Column, where unreacted isobutylene is converted into MTBE, which is recovered from the bottom and sent to storage. The overhead stream is routed to a Wash Column, where methanol is recovered, distilled, and recycled to the reactor, while a hydrocarbon stream is sent to the Depropanizer Column, which recycles a C4 stream to the Deisobutanizer.
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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 MTBE 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 MTBE 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 MTBE 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 MTBE 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 MTBE Production Cost Reports
MTBE Production from Isobutylene
This report presents a techno-economic analysis of MTBE production from methanol and isobutylene in the Unites States. In this process, similar to UOP Ethermax process, a isobutylene-rich stream obtained from an isobutane dehydrogenation plant is etherified with methanol, producing MTBE.
Details: 700 kta United States-based plant | Q3 2024 | 107 pages | Issue D | From $1,199 USD
MTBE Production from Raffinate-1
This study provides an economical analysis of Methyl tert-Butyl Ether (MTBE) production from a raffinate-1 stream and methanol using a process similar to UOP's Ethermax process for isobutylene etherification in China. In this process, isobutylene from raffinate-1 is submitted to etherification with methanol in a conventional reactor and in a reactive distillation column.
Details: 700 kta China-based plant | Q3 2024 | 107 pages | Issue A | From $999 USD
MTBE Production from FCC C4 Raffinate
This process examined provides an economical analysis of Methyl tert-Butyl Ether (MTBE) production from FCC C4 raffinate and methanol using a process similar to UOP's Ethermax process for isobutylene etherification in China. In this process, isobutylene from FCC C4 raffinate is submitted to etherification with methanol in a conventional reactor and in a reactive distillation column.
Details: 700 kta China-based plant | Q3 2024 | 107 pages | Issue B | From $999 USD
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Methanol Production from Natural Gas (Combined Reforming)
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Details: 1700 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $799 USD
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