Commodity Production Costs Report

Styrene Production from Ethane & Benzene (H2 as Co-Product)

Styrene Operating Costs & Plant Construction Costs

750 kta United States-based plant | 107 Pages | Issue C | Q3 2024
Starting at $1,199 USD | See Report Editions Prices

This report presents the economics of Styrene production from ethane and benzene in the United States, with pure hydrogen as by-product. In this report, ethylbenzene (EB) is first generated from benzene and recycled ethylene. Then, fresh ethane and the EB are dehydrogenated to form ethylene and Styrene. The process analyzed is based on concepts proposed in patents issued to Dow and Snamprogetti.

The report provides a comprehensive study of Styrene production and related Styrene production cost, covering three key aspects: a complete description of the Styrene production process examined; an in-depth analysis of the related Styrene plant capital cost (Capex); and an evaluation of the respective Styrene plant operating costs (Opex).

The Styrene 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 Styrene 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 Styrene 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): ?

Styrene Production Cost Report Process Overview
Products

Styrene. Styrene is a largely available commodity generally produced from ethylbenzene by several means. One of the commercial routes for styrene production relies on the alkylation of benzene with ethylene for generating the ethylbenzene, which is then dehydrogenated to styrene in vapor phase with steam.

Hydrogen. The hydrogen molecule, H2, is the normal state of pure hydrogen, even though hydrogen can be found in its atomic form under specific conditions. It is a very stable molecule, not usually reactive under normal conditions. Essentially, molecular hydrogen is produced industrially by three different methods: hydrocarbons steam reforming, hydrocarbons partial oxidation and water electrolysis. Hydrogen can also be obtained as a by-product recovered in processes such as the manufacture of styrene from ethylbenzene.

Raw Materials

Ethane. Ethane is a colorless, odorless gas with the chemical formula C2H6. The main commercial sources of ethane are wet natural gases and refinery waste gases. Ethane is the second largest component of natural gas, only after methane. In natural gas from shale (or shale gas), the ethane content can reach up to 16% by volume. On industrial scale, it is separated from methane by liquefaction at cryogenic temperatures. The main use of ethane is as petrochemical feedstock for Ethylene manufacturing. In some cases, ethane is not separated from natural gas and it is burnt along with methane as fuel.

Benzene. Benzene (C6H6) is a flammable and volatile liquid. As the most simple aromatic hydrocarbon, it is used as an intermediate to produce many important chemicals, such as styrene (raw material for polystyrene and synthetic rubber), cyclohexane (used in nylon production), alkylbenzenes (used in detergent industry), aniline (used to produce dyes and polyurethanes), and chlorobenzenes. Also, benzene is used to produce pharmaceuticals, specialty chemicals, plastics, and pesticides. It occurs naturally in crude oil and coal tar.

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  • Production Process Information
  • Process Consumptions
  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
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 80 Pages | 22 Tables | 9 Images

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  • Production Process Information
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  • Operating Cost Summary
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 90 Pages | 28 Tables | 13 Images

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Table of Contents


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  • Production Process Information
  • Process Consumptions
  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
  • Production Costs Datasheet
  • Plant Capital Cost Details
  • Operating Cost Details
  • Plant Cost Breakdowns
  • Plant Capacity Assessment
  • Process Flow Diagrams
  • Costs in Different Countries Add-on
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  • 107 Pages | 34 Tables | 22 Images
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Content Highlights

Plant Capital Cost Summary

Summary outlining the capital cost required for building the Styrene 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 Styrene 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 Styrene 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 Styrene 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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