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This report presents a cost analysis of 1-Butene production from ethylene. The process examined is similar to the Axens Alphabutol Process. In this process, ethylene is dimerized into butenes with high selectivity for 1-Butene. Main product 1-Butene is then separated from raffinate-2 byproduct. This report was developed based essentially on the following reference(s): Keywords: Dimerization, Axens, Alphabutol, Linear Alpha Olefins, Ethene, SABIC
This report presents a cost analysis of High Density Polyethylene (HDPE) bimodal production from ethylene and 1-butene using a gas phase process. The process examined is similar to Univation UNIPOL process. This report was developed based essentially on the following reference(s): (1) US Patent 8957167, issued to Univation in 2015 (2) US Patent 20030171512, issued to Univation in 2003 (3) US Patent 8378029, issued to Univation in 2013 Keywords: Ethene, PE, Butylene, Copolymer
This report presents a cost analysis of Linear Alpha Olefins (LAO) production from ethylene. The process examined is similar to Chevron Phillips process. In this process, ethylene is oligomerized to produce Linear Alpha Olefins ranging from C4 to C30+. This report was developed based essentially on the following reference(s): (1) "Olefins, Higher", Kirk-Othmer Encyclopedia of Chemical Technology, 5th edition (2) US Patent 5510556, issued to Chevron in 1996 Keywords: Ethene, Ethylene Oligomerization, Gulf Oil Chemicals Company
This report presents a cost analysis of Linear Low Density Polyethylene (LLDPE) production from polymer grade (PG) ethylene and 1-octene using a solution process. The process under analysis is similar to NOVA Chemicals Advanced SCLAIRTECH process. This report examines one-time costs associated with the construction of a United States-based plant and the continuing costs associated with the daily operation of such a plant. More specifically, it discusses: * Capital Investment, broken down by: - Total fixed capital required, divided in production unit (ISBL); infrastructure (OSBL) and contingency - Alternative perspective on the total fixed capital, divided in direct costs, indirect costs and contingency - Working capital and costs incurred during industrial plant commissioning and start-up * Production cost, broken down by: - Manufacturing variable costs (raw materials, utilities) - Manufacturing fixed costs (maintenance costs, operating charges, plant overhead, local taxes and insurance) - Depreciation and corporate overhead costs * Raw materials consumption, products generation and labor requirements * Process block flow diagram and description of industrial site installations (production unit and infrastructure) This report was developed based essentially on the following reference(s): US Patent 6319996, issued to Nova Chemical in 2001 Keywords: Ethene, PE, Methylpentane, Stirred-Reactor, Dual-Reactor
This report presents a cost analysis of Ethylene Dichloride (EDC) production from ethylene and chlorine using a direct chlorination process. The process examined is similar to Vinnolit process. This process consists in a liquid-phase low temperature chlorination (LTC). This report examines one-time costs associated with the construction of a United States-based plant and the continuing costs associated with the daily operation of such a plant. More specifically, it discusses: * Capital Investment, broken down by: - Total fixed capital required, divided in production unit (ISBL); infrastructure (OSBL) and contingency - Alternative perspective on the total fixed capital, divided in direct costs, indirect costs and contingency - Working capital and costs incurred during industrial plant commissioning and start-up * Production cost, broken down by: - Manufacturing variable costs (raw materials, utilities) - Manufacturing fixed costs (maintenance costs, operating charges, plant overhead, local taxes and insurance) - Depreciation and corporate overhead costs * Raw materials consumption, products generation and labor requirements * Process block flow diagram and description of industrial site installations (production unit and infrastructure) Keywords: Ethene, 1,2-Dichloroethane, Vinnolit, Westlake
This report presents a cost analysis of Bisphenol A (BPA) production from phenol and acetone. The process examined is similar to Dow's QBIS technology. In this process, BPA is produced by the reaction of acetone with phenol catalyzed by a cation-exchange resin. This report examines one-time costs associated with the construction of a United States-based plant and the continuing costs associated with the daily operation of such a plant. More specifically, it discusses: * Capital Investment, broken down by: - Total fixed capital required, divided in production unit (ISBL); infrastructure (OSBL) and contingency - Alternative perspective on the total fixed capital, divided in direct costs, indirect costs and contingency - Working capital and costs incurred during industrial plant commissioning and start-up * Production cost, broken down by: - Manufacturing variable costs (raw materials, utilities) - Manufacturing fixed costs (maintenance costs, operating charges, plant overhead, local taxes and insurance) - Depreciation and corporate overhead costs * Raw materials consumption, products generation and labor requirements * Process block flow diagram and description of industrial site installations (production unit and infrastructure) Keywords: Dow QBIS, High-Purity Bisphenol A, QCAT Resin
This report presents a cost analysis of large-scale Methanol production from natural gas. The process examined employs combined reforming for syngas generation similarly to the technologies developed by the following companies: Lurgi, Toyo, KBR, Johnson Matthey/Davy and Haldor-Topsoe. In this process, natural gas is converted into syngas in two steps: steam reforming and autothermal reforming. In the steam reformer, the natural gas reacts with steam and, in the secondary (autothermal) reformer, it reacts with oxygen. The syngas generated is then converted to Methanol.This report examines one-time costs associated with the construction of a United States-based plant and the continuing costs associated with the daily operation of such a plant. More specifically, it discusses:* Capital Investment, broken down by: - Total fixed capital required, divided in production unit (ISBL); infrastructure (OSBL) and contingency - Alternative perspective on the total fixed capital, divided in direct costs, indirect costs and contingency - Working capital and costs incurred during industrial plant commissioning and start-up* Production cost, broken down by: - Manufacturing variable costs (raw materials, utilities) - Manufacturing fixed costs (maintenance costs, operating charges, plant overhead, local taxes and insurance) - Depreciation and corporate overhead costs* Raw materials consumption, products generation and labor requirements* Process block flow diagram and description of industrial site installations (production unit and infrastructure)This report was developed based essentially on the following reference(s):(1) US Patent 8629190, issued to Lurgi in 2014; (2) US Patent 8388864, issued to Lurgi in 2013Keywords: Synthesis Gas, Lurgi MegaMethanol, Johnson Matthey, JM Davy Technologies, Toyo, Kellogg Brown and Root, KBR, Johnson Matthey/Davy, Haldor-Topsoe
This report presents a cost analysis of Lysine production from glucose syrup. The process examined is a conventional fermentation process followed by ion-exchange adsorption and crystallization steps for product recovery. In this process, a 70 wt% glucose-water syrup is used as the carbon source in the fermentation the final product obtained is L-Lysine Monohydrochloride (or L-Lysine-HCl).This report examines one-time costs associated with the construction of a United States-based plant and the continuing costs associated with the daily operation of such a plant. More specifically, it discusses:* Capital Investment, broken down by: - Total fixed capital required, divided in production unit (ISBL); infrastructure (OSBL) and contingency - Alternative perspective on the total fixed capital, divided in direct costs, indirect costs and contingency - Working capital and costs incurred during industrial plant commissioning and start-up* Production cost, broken down by: - Manufacturing variable costs (raw materials, utilities) - Manufacturing fixed costs (maintenance costs, operating charges, plant overhead, local taxes and insurance) - Depreciation and corporate overhead costs* Raw materials consumption, products generation and labor requirements* Process block flow diagram and description of industrial site installations (production unit and infrastructure)This report was developed based essentially on the following reference(s):(1) US Patent 6479700, issued to Archer-Daniels-Midland Company in 2002; (2) US Patent 7807420, issued to Paik Kwang Industrial in 2010; (3) US Patent 5268293, issued to Cheil Sugar in 1993Keywords: Dextrose, Aerobic Fermentation, Strong Acid, Cation Exchange Resin, ADM, Amino Acids, Feed-Grade, L-Lysine-HCl
This report presents a cost analysis of Propylene Glycol production from glycerol using a vapor-phase process. The process examined is similar to Davy Technologies process. In this process, technical grade glycerol (99.5 wt% glycerol content) is used as feedstock and ethylene glycol is generated as by-product. This report examines one-time costs associated with the construction of a United States-based plant and the continuing costs associated with the daily operation of such a plant. More specifically, it discusses: * Capital Investment, broken down by: - Total fixed capital required, divided in production unit (ISBL); infrastructure (OSBL) and contingency - Alternative perspective on the total fixed capital, divided in direct costs, indirect costs and contingency - Working capital and costs incurred during industrial plant commissioning and start-up * Production cost, broken down by: - Manufacturing variable costs (raw materials, utilities) - Manufacturing fixed costs (maintenance costs, operating charges, plant overhead, local taxes and insurance) - Depreciation and corporate overhead costs * Raw materials consumption, products generation and labor requirements * Process block flow diagram and description of industrial site installations (production unit and infrastructure) Keywords: Glycerin, Davy Process Technology, DPT, Propane-1,2-diol, Hydrogenolysis, Cargill, Ashland
This report presents a cost analysis of Purified Terephthalic Acid (PTA) production from p-xylene. The process examined is a conventional catalytic oxidation process. In this process, p-xylene is oxidized to Terephthalic Acid. The Terephthalic Acid from reaction passes through separation and drying steps and Crude Terephthalic Acid (CTA) is obtained as an intermediate. Subsequently, the CTA is subjected to purification via hydrogenation and PTA is separated as the final product. This report examines one-time costs associated with the construction of a United States-based plant and the continuing costs associated with the daily operation of such a plant. More specifically, it discusses: * Capital Investment, broken down by: - Total fixed capital required, divided in production unit (ISBL); infrastructure (OSBL) and contingency - Alternative perspective on the total fixed capital, divided in direct costs, indirect costs and contingency - Working capital and costs incurred during industrial plant commissioning and start-up * Production cost, broken down by: - Manufacturing variable costs (raw materials, utilities) - Manufacturing fixed costs (maintenance costs, operating charges, plant overhead, local taxes and insurance) - Depreciation and corporate overhead costs * Raw materials consumption, products generation and labor requirements * Process block flow diagram and description of industrial site installations (production unit and infrastructure) This report was developed based essentially on the following reference(s): (1) "Terephthalic Acid, Dimethyl Terephthalate, and Isophthalic Acid", Ullmann's Encyclopedia of Industrial Chemistry, 7th edition; (2) EP Patent 0824653, issued to DuPont in 2000 Keywords: Para-xylene, Paraxylene, TPA, CTA, Hydrogenation, Amoco, Catalytic Oxidation, Acetic Acid, BP, X Technology, PET, Polyethylene Terephthalate, Bromine