Commodity Production Costs Report
Propylene Production from Methanol (Methanol-to-Propylene Process)
Propylene Operating Costs & Plant Construction Costs
This report presents the economics of Polymer Grade (PG) Propylene production from methanol in the United States, using a methanol-to-propylene (MTP) process similar to Lurgi MTP. Initially, methanol is converted do dimethyl ether (DME), which is then converted to Propylene. Gasoline is generated as by-product.
The report provides a comprehensive study of Propylene production and related Propylene production cost, covering three key aspects: a complete description of the Propylene production process examined; an in-depth analysis of the related Propylene plant capital cost (Capex); and an evaluation of the respective Propylene plant operating costs (Opex).
The Propylene 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 Propylene 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 Propylene 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) Reaction and Regeneration; (2) Quench and Compression; and (3) Product Fractionation.
Reaction and Regeneration. The methanol feed is vaporized, mixed with recovered methanol and dimethyl ether (DME), superheated and sent to the DME reactor, where dehydration occurs. The product is mixed with recycled hydrocarbons and steam, before being fed into the MTP reactors. The reactors were designed with several stages for a better approach to isothermal conditions. Propylene synthesis is conducted in multiple reactors: while a set of ones conduct the reaction, the remaining are in regeneration or on stand-by mode. The recycle of olefins increases propylene yield and absorb the heat generated in the reaction. After leaving the reactors, the mixture is cooled and sent to the quench & compression steps.
Quench and Compression. The reactors outlet is quenched, where most of the water is removed. Part of this water is sent to the methanol recovery column, while the remaining is vaporized and used as dilution steam in MTP reactors. The vapor stream from quench is compressed, partially condensed, and separated into a liquid and a vapor streams.
Product Fractionation. The liquid stream from Quench & Compression is sent to the debutanizer, to separate C4- (hydrocarbons with 4 carbons or less) and DME from C5+ components. The C5+ stream from the column bottom is then separated (in the dehexanizer) into a C5/C6 stream to be recycled to the MTP reactors and into a heavier hydrocarbons stream (gasoline). The debutanizer overhead stream is mixed with the vapor stream from compression and sent to the DME removal system. The system overhead product, mainly propylene, is sent to the deethanizer, while the bottom is mostly recycled. The bottoms from the deethanizer is routed to the C3 splitter, to obtain PG propylene, while the overhead is recycled to the MTP reactors. The bottoms from the C3 splitter is purged as LPG.
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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 Propylene 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 Propylene 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 Propylene 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 Propylene 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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Details: 450 kta United States-based plant | Q3 2024 | 107 pages | Issue D | From $799 USD
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