Acetylene Production from Calcium Carbide
Acetylene Production Costs Report | Issue D | Q4 2024
| Report Details |
| 200 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 200 kta (kilo metric ton per annum) United States-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.
Report Abstract
This study presents the economics of Acetylene production from calcium carbide in the United States via wet process. In the process, calcium carbide reacts with water to form Acetylene. Hydrated lime is generated as by-product.
The report provides a comprehensive study of Acetylene production and related Acetylene production cost, covering three key aspects: a complete description of the Acetylene production process examined; an in-depth analysis of the related Acetylene plant capital cost (Capex); and an evaluation of the respective Acetylene plant operating costs (Opex).
The Acetylene 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 Acetylene 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 Acetylene plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Process Schematic
The process under analysis comprises three major sections: (1) Acetylene generation; (2) Purification; and (3) Carbide Lime Recovery.
Acetylene generation. Initially, the calcium carbide is mixed with the water, which is present in large excess in the chamber (carbide-to-water principle) to help dissipate the heat of reaction between these two components generating the gaseous acetylene. A gaseous stream of acetylene and impurities, mainly sulfur and phosphorus compounds, exits from the generators top and proceeds to the purification section while a liquid stream of lime slurry exists from the bottom of the gasification tank as a by-product.
Purification. The acetylene formed first passes through a scrubbing tower, where the solids conveyed by the gas are removed. Subsequently, the Acetylene is fed to an absorption column where it flows countercurrent to a sulfuric acid solution, which acts as an oxidizing/neutralizing agent for the removal of impurities present in the Acetylene stream. The Acetylene is then passed through a caustic scrubber, where sulfur dioxide formed in the absorber column is removed by a caustic wash. Finally, the Acetylene is compressed, cooled and dried in silica gel beds before being sent directly to nearby facilities where it is consumed.
Carbide Lime Recovery. The carbide lime slurry coming from the Generator is fed to a decanter, in which a lime sludge is obtained and sent to a press filter to reduce the humidity to about 30%. The carbide lime cake is dried, crushed and sent to warehouses at the facility’s OSBL to be stored.
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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
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Acetylene 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 Acetylene 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 Acetylene 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 Acetylene 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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