Ethylene Production from Methanol
Ethylene Production Costs Report | Issue L | Q3 2024
| Report Details |
| 450 kta United States-based plant | Q3 2024 | 107 pages |
This report presents a cost analysis of a 450 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 report analyses the economics of Ethylene production from methanol in the United States. The process examined in this report is similar to UOP/Norsk Hydro (now Ineos) MTO (Methanol-to-Olefins) process. Initially, methanol is converted into dimethyl ether, which is further dehydrated to olefins. Ethylene and propylene are generated as co-products.
The report provides a comprehensive study of Ethylene production and related Ethylene production cost, covering three key aspects: a complete description of the Ethylene production process examined; an in-depth analysis of the related Ethylene plant capital cost (Capex); and an evaluation of the respective Ethylene plant operating costs (Opex).
The Ethylene 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 Ethylene 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 Ethylene 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) Reaction and regeneration; (2) Quench, compresion and caustic wash; and (3) Product fractionation.
Reaction and regeneration. Methanol feed is vaporized, mixed with recovered methanol, superheated and sent to the fluidized-bed reactor. In the reactor, methanol is first converted to dimethylether (DME) intermediate and then converted to olefins with a very high selectivity to ethylene and propylene. During the reaction, coke accumulates on the catalyst, which is circulated to the fluidized-bed regenerator system. In the regenerator, the coke is removed by combustion with air to keep the catalyst activity.
Quench, compression and caustic wash. The output from the reaction and regeneration is quenched, where most of water and non-reacted methanol is removed. The vapor stream from the quench stage is compressed and sent to a caustic wash column for CO2 removal. The gas stream free of CO2 is then dried and sent to next section.
Product fractionation. The dried stream is sent to the deethanizer column, where ethylene is separated from C3+ hydrocarbons as the overhead product. The ethylene rich stream is compressed and fed to the acetylene reactor for selective acetylene hydrogenation to ethane. The acetylene reactor effluent is sent to the demethanizer column, where an ethylene-ethane mixture is separated from a light stream. The C2 mixture is then routed to the C2 splitter, to obtain polymer grade (PG) ethylene product as the overhead. The C3+ stream is fed to the depropanizer column. The bottom product, composed mainly by C4+ hydrocarbons is sent to a debutanizer for recovering of mixed C4 and pyrolysis gasoline. The depropanizer column distillate, mainly containing a propylene-propane mixture, is fed to the C3 splitter column. In the C3 splitter, PG propylene is obtained as the overhead product.
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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 Ethylene 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 Ethylene 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 Ethylene 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 Ethylene 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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