We used HYSYS software to model and simulate two integrated plants: one for natural gas processing and one for ethylene production. This allowed us to obtain reasonable initial estimates of the essential parameters for designing and operating the plants, such as mass and energy balances, equipment specifications, and utility requirements. We also used the economic analyzer feature of HYSYS and other correlations from literature to estimate the capital and operating costs of the entire process. We found that the capital costs are relatively high compared to the annual revenue (1.2-1.6 MMM$ versus 2 MMM$), which means that the payback period will depend largely on the market conditions. The most important factor that affects the profitability of this process is the price of raw shale gas, which is the main feedstock. This price is subject to fluctuations and uncertainties due to supply and demand factors. However, we are optimistic that the price of raw shale gas will decrease in the future, and the prices of ethylene and crude oil, which are the main products, will increase to more normal levels. This analysis shows that this process has a significant economic potential over the long run, especially if it can take advantage of economies of scale and technological improvements.
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In this report, we present the details of our process design and economic analysis. We start by describing the natural gas processing plant, which consists of four main sections: acid gas removal, dehydration, nitrogen rejection, and NGL recovery. We explain the operating conditions and equipment selection for each section, and present the mass and energy balances for the plant. We also discuss the environmental and safety aspects of the plant, such as emissions, waste disposal, and hazard analysis.
Next, we describe the ethylene production plant, which consists of three main sections: steam cracking, compression and refrigeration, and separation. We explain the operating conditions and equipment selection for each section, and present the mass and energy balances for the plant. We also discuss the environmental and safety aspects of the plant, such as emissions, waste disposal, and hazard analysis.
Finally, we present the economic analysis of the integrated process. We estimate the capital costs of the plants based on the equipment sizes and costs obtained from HYSYS and other correlations. We also estimate the operating costs of the plants based on the utility consumption, raw material costs, labor costs, maintenance costs, and taxes. We then calculate the annual revenue of the process based on the product prices and production rates. We perform a sensitivity analysis to evaluate the effect of different parameters on the profitability of the process, such as raw shale gas price, ethylene price, crude oil price, plant capacity, and discount rate. We also calculate the net present value (NPV), internal rate of return (IRR), and payback period (PBP) of the process under different scenarios. e0e6b7cb5c