PG Ethylene from Ethanol (Similar to Braskem Process)
Ethylene Production Costs Report | Issue N | Q4 2024
| Report Details |
| 250 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 250 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 costs associated with Green Polymer Grade (PG) Ethylene production from ethanol in the United States using a process similar to the processes developed by Braskem and Petrobras. In this process, the reaction system is composed of multiple reactors and multiple furnaces.
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; (2) Quench, wash, and compression; and (3) Purification.
Reaction. Fresh ethanol feed is combined with recycled ethanol recovered downstream then vaporized. The stream is superheated in a furnace and fed to the first reactor. During reaction, the temperature drops and the output stream must be re-heated before entering the next reactor. This is repeated until the fourth reactor, where ethanol reaches 99% of conversion.
Quench, wash, and compression. The reaction outlet stream primarily consists of Ethylene and water, with some unreacted ethanol and impurities. The stream is quenched to condense most of the water and ethanol, compressed, washed with water and a caustic soda solution to remove oxygenated impurities, then dried. The ethanol content of all effluents produced is recovered and recycled to the reactors.
Purification. Two distillation columns are employed for further purification of the Ethylene. The first column is a C2 splitter, responsible for the removal of undesired hydrocarbons. The second column is a CO stripper, removing carbon monoxide and remaining light impurities. The polymer grade ethylene (99.9 wt%) product is obtained in the bottoms of the stripper column.
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Production Process Information
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Production Process Information
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Production Costs Datasheet
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Operating Cost Details
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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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