Commodity Production Costs Report

Vinyl Chloride Production from Ethane and Chlorine

Vinyl Chloride Operating Costs & Plant Construction Costs

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

This study reviews the costs associated with Vinyl Chloride production directly from ethane and chlorine. The process examined is an early stage process similar to that developed by European Vinyls Corporation, now owned by INEOS. The process is a direct ethane to vinyl chloride monomer route. The economic assessment assumes 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 Overview
Product

Vinyl Chloride. Vinyl chloride, or vinyl chloride monomer (VCM), is a major chemical commodity, with worldwide importance related to its industrial use as the precursor to PVC. VCM is also used in a wide variety of copolymers. Inherent flame-retardant properties, wide range of plasticized compounds, and low cost of polymers produced from vinyl chloride have made it in fact a major industrial chemical, manufactured in about fifty countries. First commercially produced by catalytic hydrochlorination of acetylene, vinyl chloride nowadays is largely produced through ethylene-based, balanced vinyl chloride process. VCM production routes development have been tightly connected to the availability of key raw materials, particularly ethylene and chlorine, along with concerns related to energy efficiency, environmental impact, safety, and process reliability. Most of the existing VCM plants are actually integrated to EDC plants, where direct chlorination and oxychlorination processes are employed in parallel for EDC production.

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.

Chlorine. Chlorine figures among the most important chemical commodities. It is an indispensable intermediate in the chemical industry, employed in the manufacture of a multitude of end products (e.g. materials of construction, solvents, pesticides, etc). Most of chlorine produced on commercial scale is based on electrolysis of aqueous sodium chloride (brine), which also generates caustic soda and hydrogen as co-products (chlor-alkali processes).

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Features
  • Production Process Information
  • Process Consumptions
  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
  • Production Costs Datasheet
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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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Updated with Q3 2024 Data

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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
  • See All Features

  • 107 Pages | 34 Tables | 22 Images
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  • Updated with Q3 2024 Data
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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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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.

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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

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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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Chlorine Production from Sodium Chloride (Diaphragm Process)

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