Abstract. Process Economics Program Report No. 146 BULK CHEMICALS FROM SYNTHESIS GAS. (.Iune 1982)

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1 Abstract Process Economics Program Report No. 146 BULK CHEMICALS FROM SYNTHESIS GAS (.Iune 1982) This report covers the technology and costs of manufacture of four chemicals from synthesis gas: acetic anhydride, vinyl acetate, ethylene, and ethanol. Six processes are presented: two each for the manufacture of acetic anhydride and ethylene, and one each for the manufacture of vinyl acetate and ethanol. The economics of each of the processes is compared with that for the respective conventional technology. PEP 80 MA/RWS

2 Report No. 146 BULK CHEMICALS FROM SYNTHESIS GAS by MICHAEL ARNE SATISH NIRULA and HAROLD W. SCHEELINE June 1982 A private report by the PROCESS ECONOMICS PROGRAM Menlo Park, California 94025

3 For detailed marketing data and information, the reader is referred to one of the SRI programs specializing in marketing research. The CHEMICAL ECONOMICS HANDBOOK Program covers most major chemicals and chemical products produced in the United States and the WORLD PETROCHEMICALS Program covers major hydrocarbons and their derivatives on a worldwide basis. In addition, the SRI DIRECTORY OF CHEMICAL PRODUCERS services provide detailed lists of chemical producers by company, product, and plant for the United States and Western Europe. ii

4 CONTENTS 1 INTRODUCTION SUMMARY... 3 Acetic Anhydride... 3 Acetic Anhydride from Carbon Monoxide and Methanol via Acetic Acid and Ketene... 4 Acetic Anhydride from Carbon Monoxide and Methanol via Methyl Acetate... 6 Vinyl Acetate... 7 Ethylene by Direct Fischer-Tropsch Synthesis Ethylene from Methanol Ethanol ECONOMIC BASES AND PRICE PROJECTIONS ACETIC ANHYDRIDE FROM CARBON MONOXIDE AND METHANOL Introduction Chemistry Review of Processes Process Description Process Discussion Cost Estimates Acetic Anhydride via Carbonylation of Methyl Acetate Chemistry Review of Processes Process Description Process Discussion Cost Estimates VINYL ACETATE FROM METHANOL AND SYNTHESIS GAS Chemistry Process Review Process Description Process Discussion Cost Estimates iii

5 CONTENTS 6 ETHYLENE FROM SYNTHESIS GAS Chemistry Process Review Process Description Process Discussion Cost Estimates ETHYLENE FROM METHANOL Chemistry Process Review Process Description Process Discussion Cost Estimates ETHANOL FROM SYNTHESIS GAS Chemistry Process Review Process Description Process Discussion Cost Estimates CITED REFERENCES PATENT REFERENCES iv

6 ILLUSTRATIONS Ethylene Product Values Price Projections, Ethanol Product Values Price Projections Block Diagram for Two Schemes to Acetic Anhydride from Syn Gas (Illustrating Boundaries Assumed in Economic Evaluation) FlowSheet on Product Value, FlowSheet on Product Value Vinyl Acetate from Methyl Acetate and Synthesis of Gas FlowSheet on Production Cost + 25%/yr ROI Vinyl Acetate from Ethylene and Acetic Acid on Production Cost + 25%/yr ROI FlowSheet on Production Cost + 25%/yr ROI Effect of Conversion on Total Fixed Capital Effect of Conversion on Production Cost + 25%/yr ROI

7 ILLUSTRATIONS 7.1 Ethylene from Methanol Flowsheet Ethylene from Methanol on Production Cost + 25%/yr ROI Ethanol by Direct Synthesis from Synthesis Gas Flowsheet Ethanol by Direct Synthesis from Synthesis Gas on Production Cost + 25%/yr ROI vi

8 TABLES Summary of Acetic Anhydride Economics... 5 Summary of Vinyl Acetate Economics... 8 Summary of Ethylene Economics Cost Projections Ethylene from Methanol Cost Projections Ethylene from Gas Oil by Steam Cracking Cost Projections Summary of Ethanol Economics Ethanol from Synthesis Gas Cost Projections Ethanol from Ethylene Cost Projections Projected U.S. Prices of Feeds and By-Products Patent Summary Design Bases Major Equipment Stream Flows Capital Investment Production Costs Patent Summary Assumptions for Methyl Acetate Synthesis Design Case Assumptions' for Water Removal and Carbonylation Stages vii

9 TABLES StreamFlows... (Including Ester Synthesis) Major Equipment (Including Ester Synthesis) Capital Investment (Including Ester Synthesis) Production Costs Design Bases and Assumptions Stream Flows Major Equipment Capital Investment Production Costs Vinyl Acetate from Ethylene and Acetic Acid by Vapor Phase Process Production Costs Patent Summary... Design Bases Major Equipment StreamFlows... Capital Investment viii

10 TABLES 6.6 Production Costs ' Ethylene from Methanol Patent Review Ethylene from Methanol Design Bases and Assumptions Ethylene from Methanol Major Equipment Ethylene from Methanol Stream Flows......, Ethylene from Methanol (Fluid Bed Zeolite Catalyst Process) Capital Investment Ethylene from Methanol (Fluid Bed Zeolite Catalyst Process) Production Costs Ethanol by Direct Synthesis from Synthesis Gas Patent Summary Ethanol by Direct Synthesis from Synthesis Gas Design Bases Ethanol by Direct Synthesis from Synthesis Gas Major Equipment Ethanol by Direct Synthesis from Synthesis Gas Stream Flows Ethanol by Direct Synthesis from Synthesis Gas Capital Investment Ethanol by Direct Synthesis from Synthesis Gas Production Costs ix

Abstract Process Economics Program Report 37B ACETIC ACID AND ACETIC ANHYDRIDE (November 1994)

Abstract Process Economics Program Report 37B ACETIC ACID AND ACETIC ANHYDRIDE (November 1994) This Report presents preliminary process designs and estimated economics for the manufacture of acetic acid