Commodity Production Costs Report
Propylene Production from Vacuum Gas Oil (Catalytic Cracking)
Propylene Plant Capital & Operating Cost Analysis | China | Q1 2026
This report presents the economics of Polymer Grade (PG) Propylene production from vacuum gas oil (VGO). The process examined is similar to Sinopec Deep Catalytic Cracking (DCC) technology. This process uses fluid catalytic cracking (FCC) principles with enhancements to maximize the production of Propylene. In addition to Propylene, the process also generates propane, C4 fraction, C5+ naphtha and fuel oil as by-products.
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.
The process under analysis comprises two major sections: (1) Cracking; and (2) Fractionation.
Cracking. Vacuum gas oil are treated with hydrogen over a selective catalyst for the removal of impurities. The treated oil is cracked in a vertical reactor riser, in two separate and distinct cracking zones. The vacuum gas oil is first cracked mainly to gasoline and then to olefins. Zeolite catalyst is used. The spent catalysts are then fed to a regenerator where coke (a carbonaceous by-product from cracking reactions) deposited in the catalysts is burned with air at high temperatures.
Fractionation. The reactor effluent is passed through fractionation and concentration steps. Initially, in a fractioner, fuel oil is separated from a gaseous stream rich in gasoline, olefins and light ends. Part of this oil is directed to hydrotreater, the other part is sold as fuel. The main stream is compressed and fed to a high-pressure (HP) separator, in which a fuel gas rich in C3 and C2 components are removed. This stream is further treated to recover and recycle residual gasoline. Products stream is fed to a stripper column, where C2- components are stripped off and sent back to HP separator. The main products are sent to a series of columns for separation. First, pyrolysis gas is obtained, then crude C4s and finally propane and high purity propylene.
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Professional report based on Q1 2026 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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Other Propylene Production Cost Reports
Propylene Production from Propane (Moving-Bed Reactor)
This study presents the economics of Polymer Grade (PG) Propylene production from propane. The process consists in the dehydrogenation of propane, carried out in a moving-bed reactor, similar to UOP Oleflex. The economic analysis performed assumes a plant located in the United States.
Details: 550 kta United States-based plant | Q1 2026 | 107 pages | Issue B | From $799 USD
Propylene Production from Propane (Fixed-Bed Reactor)
This report examines the costs related to Polymer Grade (PG) Propylene production from propane in the United States. The process examined in this report is based on the dehydrogenation of propane carried out in fixed-bed reactors, similar to Lummus CATOFIN.
Details: 590 kta United States-based plant | Q1 2026 | 107 pages | Issue C | From $799 USD
Propylene Production from Propane (Oxydehydrogenation)
The report under analysis presents the economics of Polymer Grade (PG) Propylene production from propane in the United States. The process examined in this report uses a two-step dehydrogenation process (steam reforming/oxyreaction), similar to Uhde STAR.
Details: 450 kta United States-based plant | Q1 2026 | 107 pages | Issue D | From $799 USD
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