Commodity Production Costs Report

Vinyl Chloride Production from Acetylene

Vinyl Chloride Operating Costs & Plant Construction Costs

280 kta United States-based plant | 107 Pages | Issue C | Q3 2024
Starting at $799 USD | See Report Editions Prices

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.

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): ?

Vinyl Chloride Production Cost Report Process Schematic

The process under analysis comprises three major sections: (1) Reaction; (2) VCM Purification; and (3) Acetylene Recovery.

Reaction. Compressed acetylene is passed through dryers for removal of any residual moisture and then fed to guard beds to remove any contaminants that may damage catalyst activity. Purified acetylene is mixed with anhydrous hydrogen chloride. The gaseous raw materials are fed to a multi-tubular heat exchanger, in which tubes are packed with catalyst and a cooling fluid is fed to the shell to remove the heat generated by the reaction.

VCM Purification. The reaction effluent is twice scrubbed with water and caustic solution to remove any hydrogen chloride. A diluted hydrochloric acid is sent to hydrogen chloride recovery and wastewater is disposed. Gaseous effluent is recompressed, cooled and fed to a three-phase separator. The uncondensed light ends are transferred to the Acetylene Recovery.The organic liquid phase is transferred to a column for further purification. Vinyl Chloride crude product is recovered as the bottom stream. VCM crude product is fed to the final purification column, where purified VCM is recovered in the column overhead and stored.

Acetylene Recovery. Uncondensed light ends from the Dehydration Column are fed to an absorption column, in which acetylene is absorbed in liquid chlorinated hydrocarbons. Acetylene absorbed is recovered in a stripping column. The acetylene removed as overhead stream is recycled to reactor feed.

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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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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
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 90 Pages | 28 Tables | 13 Images

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Table of Contents


Features
  • 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 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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