Commodity Production Costs Report
Vinyl Chloride from Ethylene and Chlorine (By-Product: HCl)
Vinyl Chloride Operating Costs & Plant Construction Costs
This study approaches a detailed cost analysis of Vinyl Chloride (VCM) production from ethylene and chlorine as raw materials. Initially, ethylene is chlorinated to produce ethylene dichloride (EDC). Then, EDC is thermally cracked yielding VCM. The economic analysis presented assumes a plant located in the United States.
The report provides a comprehensive study of Vinyl Chloride production and related Vinyl Chloride production cost, covering three key aspects: a complete description of the Vinyl Chloride production process examined; an in-depth analysis of the related Vinyl Chloride plant capital cost (Capex); and an evaluation of the respective Vinyl Chloride plant operating costs (Opex).
The Vinyl Chloride 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 Vinyl Chloride 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 Vinyl Chloride 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) Reactions; (2) VCM Purification; and (3) EDC Recovery.
Reactions. Chlorine and ethylene are fed to a high-temperature chlorination reactor, filled with EDC as the reaction medium. The heat of the highly exothermal reaction is removed by boiling off EDC. A complex inorganic compound is used as catalyst. About 99% of ethylene and almost 100% of chlorine are converted, with high selectivity to EDC. The EDC from the EDC Tank is mixed with recycled EDC and is preheated, vaporized and subsequently cracked in a pyrolysis furnace heated by fuel combustion. The cracking reaction is endothermic and generates VCM, HCl, by-products of various chemical structures and coke. The furnace operates at temperatures above 480 °C and pressure of about 16 bar. Cracking rates of up to 60% are achieved, with selectivity to VCM greater than 98%.
VCM Purification. The output from the pyrolysis furnace, containing the VCM produced, is quenched to minimize coke formation. The overhead from the quench is sent to the HCl Column. Hydrogen chloride stream recovered in column overhead is sent to a section, where acetylene impurity is hydrogenated. After, it is sent to the consumer. The column bottoms, comprising unconverted EDC and VCM, are fed to a VCM column, where VCM is separated from unconverted EDC. Residual HCl present in VCM stream is removed in a stripper and recycled to the first column, while VCM product is stored.
EDC Recovery. Unreacted EDC is fed to the High-Boil column, for high-boiling compounds removal. The bottom product from the High-Boil column and the bottom product from quench are fed to the Vacuum Column, where more EDC is recovered. EDC streams are recycled to cracking, while heavies is sent to a waste disposal system.
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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 Vinyl Chloride 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 Vinyl Chloride 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 Vinyl Chloride 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 Vinyl Chloride 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 Vinyl Chloride Production Cost Reports
Vinyl Chloride Production from Acetylene
This feasibility study reviews a typical hydrochlorination process for Vinyl Chloride production from acetylene. In this process, anhydrous hydrogen chloride is reacted in vapor phase with acetylene over a mercuric chloride catalyst producing Vinyl Chloride. The economic analysis presented is based on the construction of an industrial plant in the United States.
Details: 280 kta United States-based plant | Q3 2024 | 107 pages | Issue C | From $799 USD
Vinyl Chloride from Ethylene and Chlorine (Balanced Process)
This study presents the economics of Vinyl Chloride (VCM) production from ethylene and chlorine in the United States. Initially, ethylene is chlorinated to produce ethylene dichloride (EDC). Then, EDC is thermally cracked yielding VCM and HCl. The HCl produced and ethylene are reacted with oxygen, yielding more EDC. This leads to a so called “balanced process”.
Details: 500 kta United States-based plant | Q3 2024 | 107 pages | Issue D | From $1,499 USD
Vinyl Chloride Production from Ethylene and EDC
This report presents the production cost of Vinyl Chloride from ethylene and ethylene dichloride (EDC) in the United States. The process examined combines two process. First, Vinyl Chloride is produced via thermal cracking of EDC, which generates hydrogen chloride (HCl). It is then used as raw material with ethylene in the EDC production via oxychlorination.
Details: 500 kta United States-based plant | Q3 2024 | 107 pages | Issue E | From $1,199 USD
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