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Light Olefin Oligomerisation to Jet-Range Hydrocarbons

Screening-level sizing and cost model for a catalytic oligomerisation unit converting light olefins to jet-range (kerosene-range) hydrocarbons, including recycle of light ends, primary separation, utilities, and equipment-purchase CAPEX with scaling curves.

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alexi

I do low-carbon energy stuff for 10 years & build things I wish existed.

Inputs

Select an oligomerisation catalyst/flowsheet archetype to apply different reference CAPEX and utility intensities.

Mass yield of jet-range hydrocarbons from olefin feed at steady operation (single-pass lumped yield).

Nameplate light-olefin feed rate entering the oligomerisation section (battery limits).

t/h

Average utilisation over the year (includes downtime and turndown).

min 10 · max 100 · step 1 · %

Jet-range hydrocarbon outlet flow

Unsaturated jet-range hydrocarbons produced (average hourly, at nameplate)

…t/h

Light-ends recycle flow

Recovered light ends recycled back to the reactor section

…t/h

Annual olefin feed requirement

Total olefin required at battery limits per year

…t/year

Annual jet-range hydrocarbon production

Based on capacity factor and hours per year

…t/year

Light ends generated

Non-jet fraction (C3–C8-like) leaving oligomerisation section before recovery

…t/h

Design

Number of reactor trains

Major oligomerisation reactor trains (parallel units)

…count

Reactor straight-side height (per train)

Derived from assumed aspect ratio H/D

…m

Reactor internal diameter (per train)

Cylindrical approximation using aspect ratio H/D

…m

Reactor volume per train

Catalyst bed volume proxy per parallel reactor train

…m3

Primary separation column height

Typical installed height assumption for screening

…m

Primary separation column diameter

Simplified flux-based sizing for the main separator/distillation column

…m

Total plot space required

Installed footprint with access/integration margin

…m2

Results

Specific equipment purchase CAPEX (scaled)

Clamped specific CAPEX after applying power-law scaling

…EUR/(t/h)

Total equipment purchase CAPEX

Purchased equipment only (excludes installation/indirects/owner’s costs)

…EUR

CAPEX bucket: reactors + catalyst system

Share of equipment purchase CAPEX

…EUR

CAPEX bucket: primary separation

Share of equipment purchase CAPEX

…EUR

CAPEX bucket: recycle compression

Share of equipment purchase CAPEX

…EUR

CAPEX bucket: auxiliary systems

Share of equipment purchase CAPEX

…EUR

Annual fixed O&M cost

Fixed operations & maintenance cost component

…EUR/year

Annualized catalyst replacement cost

Periodic replacement annualized over a replacement interval

…EUR/year

Annual utilities cost

Electricity + heat based on specific intensities and user prices

…EUR/year

Energy Consumption

Net heat duty (average)

Indicative heating/cooling duty allocated to the unit operation

…MWth

Electric power (average)

Includes recycle compression and auxiliaries in a lumped specific intensity

…MW

Annual electricity consumption

Total electricity over the year at the selected capacity factor

…MWh/year

Recycle compressor power (average)

Indicative electricity subset attributed to recycle compression

…MW

Levelized Cost Indicators

Amortization period used with the discount rate in the CRF.

year

Decimal fraction (e.g., 0.08 = 8%). Used in the capital recovery factor (CRF).

ratio

Blended electricity price used for unit electricity cost (and for indicative upstream electricity reporting).

EUR/MWh

Use as a purchased feed price or as an internal valuation for olefin intermediate in an e-fuels route.

EUR/t

min 0 · max 5000 · step 10 · EUR/t

Annual olefin feed cost

Feedstock cost using user-provided olefin price

…EUR/year

Levelized cost (incl. olefin feed)

Total annual cost divided by annual jet-range production

…EUR/t

Cost of thermal energy (e.g., steam, hot oil, or fuel-based heat) for net heat duty.

EUR/MWhth

Levelized processing cost (excl. olefin feed)

Useful when olefins are an internal intermediate with a transfer price

…EUR/t

Levelized cost per energy (incl. olefin feed)

Total annual cost divided by annual product energy (LHV basis)

…EUR/MWh

About

Calculator context

Introduction

This calculator provides a pre-feasibility (screening) estimate of material flows, key equipment sizes, plot space, utilities, and costs for a catalytic oligomerisation unit that upgrades light olefins into unsaturated jet-range hydrocarbons. It is intended for global use (no country-specific pricing embedded) and uses standard screening practices: mass-yield balance, rule-of-thumb equipment sizing, and power-law CAPEX scaling.

Methodology

The model converts a user-provided olefin inlet rate to jet-range product and light-ends by a single-pass yield, then estimates recycle, utilities, and major equipment geometry.

Key equations (variables defined in parentheses):

  • Operating time and annual production:
    • operating_hours_per_year = hours_per_year × capacity_factor (capacity_factor in fraction)
    • annual_olefin_t = olefin_inlet_tph × operating_hours_per_year
    • jet_outlet_tph = olefin_inlet_tph × yield_fraction
    • annual_jet_t = jet_outlet_tph × operating_hours_per_year
  • Light ends and recycle:
    • light_ends_tph = olefin_inlet_tph − jet_outlet_tph
    • recycle_tph = light_ends_tph × recycle_recovery_fraction
  • Utilities:
    • heat_duty_MWth = olefin_inlet_tph × specific_heat_MWhth_per_t
    • electric_power_MW = olefin_inlet_tph × specific_electricity_kWh_per_t ÷ 1000
  • Reactor sizing (fixed-bed screening):
    • volumetric_flow_m3h = (olefin_inlet_tph × 1000) ÷ density
    • reactor_volume_total_m3 = volumetric_flow_m3h ÷ LHSV
    • n_units = ceil(reactor_volume_total_m3 ÷ max_volume_per_train)
    • Cylinder geometry using aspect ratio H/D and V = (pi/4)×D^2×H
  • Costing (IRENA/IEA-style screening):
    • CRF = (r*(1+r)^n)/max(((1+r)^n-1),eps)
    • CAPEX scaling: capex ∝ (capacity/capacity_ref)^exponent with clamps on specific CAPEX
    • annualized_capex = capex_total × CRF
    • total_annual_cost = annualized_capex + O&M + replacement + utilities + feedstock
    • levelized_cost = total_annual_cost ÷ annual_jet_t

E-fuels scaffold integration: the calculator also reports equivalent upstream H2 and CO2 per tonne of hydrocarbon (stoichiometric from a representative jet-range hydrocarbon) and an indicative power-to-fuel efficiency using a default upstream electricity intensity (IEA/IRENA/Fraunhofer/Concawe-aligned ranges).

Applications

  • Business developer (project screening): estimate jet-range output, recycle rates, and levelized cost sensitivity to yield and olefin transfer price.
  • Process engineer (concept selection): compare technology options (catalyst system archetypes) on utilities and equipment count/size.
  • Techno-economic analyst (portfolio): generate consistent CAPEX/OPEX breakdowns (reactors / separation / recycle compression / auxiliaries) for scenario models and dashboards.

Model

136 variables — inputs, calculations and outputs, with their dependencies.

136 variables shown of 136
VariableValueUnitDepends on
10t/h—
90%—
80%—
1——
80EUR/MWh—
25EUR/MWhth—
900EUR/t—
0.08ratio—
20year—
VariableFormulaUnitDepends on
if(((<=)+(<)+(>100)+(<)+(>100)+(<1)+(>3)+(<)+(<)+(<)+(<)+(>)+(<=))>,,)bool
*—
*h/year
*—
max((-),)t/h
*kg/year
/max(,)kWh/kg
(*)/max(,)MWh/year
if(==1,,if(==2,,))MWhth/t
if(==1,,if(==2,,))kWh/t
*MWhth/year
*kg/h
/max(,)m3/h
/max(,)m3
/max(,)m2
***m2
**m2
*m2
/max(,)—
if(==1,,if(==2,,))EUR
*(^)EUR
/max(,)EUR/(t/h)
(*(+)^)/max(((+)^-),)—
if(==1,,if(==2,,))—
*(^)—
*EUR/year
(**)/max(,)t
*EUR/year
*EUR/year
-EUR/year
*kWh/year
/max(,)kWh/kg
+kWh/kg
VariableFormulaUnitDepends on
t/h
*t/h
max((-),)t/h
*t/h
*t/year
*t/year
*MWth
*(/max(,))MW
*(/max(,))MWh/year
*(/max(,))MW
max(,ceil(/max(,)))count
/max(,)m3
((*)/max((*),))^m
*m
max(sqrt((*)/max(,)),)m
m
(+++)*(+)m2
clamp(,,)EUR/(t/h)
*EUR
*EUR
*EUR
*EUR
*EUR
*EUR/year
clamp(,,)ratio
*EUR/year
(*)/max(,)EUR/year
+EUR/year
*EUR/year
+++++EUR/year
/max(,)EUR/t
/max(,)EUR/MWh
/max(,)EUR/t
(*)/max(,)t/year
(*)/max(,)t/year
/max(,)ratio

Assumptions

58 assumptions used in the calculations

  • Prevents division-by-zero and undefined operations during scaling and CRF calculations.

    Market range Not applicable

    0.000001
    Numerical stability constant

  • Converts percent inputs to fractions for calculations.

    Market range Fixed

    0.01fraction/%
    Unit conversion

  • Used to convert capacity factor to annual operating hours.

    Market range Fixed

    8760h/year
    Calendar convention

  • Converts tonnes to kilograms.

    Market range Fixed

    1000kg/t
    Unit conversion

  • Converts MWh to kWh (and used inversely for kWh to MWh in expressions).

    Market range Fixed

    1000kWh/MWh
    Unit conversion

  • Used to convert MJ-based LHV to MWh-based energy output.

    Market range Fixed

    3600MJ/MWh
    Unit conversion

  • Used to express LHV in kWh/kg when computing efficiency.

    Market range Fixed

    3.6MJ/kWh
    Unit conversion

  • Used in cylinder volume and area relations for reactor/column geometry.

    Market range Fixed

    3.141593
    Mathematical constant

  • Used for non-negativity clamps (e.g., max(x,0)).

    Market range Fixed

    0
    Numerical constant

  • Used for minimum unit counts and margin multipliers (1 + margin).

    Market range Fixed

    1
    Numerical constant

  • Used in geometric relations (e.g., area/diameter conversions).

    Market range Fixed

    4
    Numerical constant

  • Used to compute cube roots via x^(1/3) in the DSL.

    Market range Fixed

    0.333333
    Numerical constant

  • Defines the reference capacity at which the technology-specific reference CAPEX values apply.

    10t/h
    Reference point for cost scaling

  • Represents economies of scale for equipment purchase costs with throughput.

    0.65
    Scaling law exponent

  • Prevents unrealistically low specific CAPEX when extrapolating to large capacity.

    1500000EUR/(t/h)
    Model clamp bound

  • Prevents unrealistically high specific CAPEX when extrapolating to very small capacity.

    6000000EUR/(t/h)
    Model clamp bound

  • Captures modest reduction in fixed O&M fraction with increasing plant size.

    Market range -0.2 to 0.0

    -0.1
    O&M scaling assumption

  • Lower bound for fixed O&M fraction to avoid underestimation.

    0.02ratio
    Model clamp bound

  • Upper bound for fixed O&M fraction to avoid unrealistic escalation at small scales.

    0.08ratio
    Model clamp bound

  • Represents consumables, waste handling, minor chemicals not captured elsewhere, proportional to product.

    15EUR/t
    Screening variable O&M intensity

  • Adds access, pipe-rack, maintenance, and congestion allowance to equipment footprints.

    0.35ratio
    Plot plan allowance

  • Represents pumps, instrumentation, small exchangers, control room skids, and pipe-rack space not explicitly sized.

    600m2
    Auxiliaries footprint placeholder

  • Defines a maximum practical catalyst bed volume per train for screening; larger plants add parallel trains.

    60m3
    Modularization limit

  • Provides a reasonable fixed-bed reactor height-to-diameter ratio for preliminary geometry sizing.

    4m/m
    Geometry assumption

  • Approximates liquid-phase density of mixed light olefins under typical process conditions for volumetric sizing.

    650kg/m3
    Feed property assumption

  • Represents a screening LHSV for oligomerisation fixed-bed operation (volumetric throughput per catalyst volume).

    1.51/h
    Reactor design heuristic

  • Approximates installed reactor skid footprint per unit of reactor base area (includes clearance and piping).

    1.8m2/m2
    Footprint factor

  • Defines an allowable volumetric throughput per column cross-sectional area for screening diameter sizing.

    12m3/h/m2
    Separation sizing heuristic

  • Typical installed height for a primary distillation/separation column in screening layouts.

    25m
    Separation geometry assumption

  • Avoids unrealistically small diameters for constructability and hydraulics in screening.

    1.2m
    Minimum practical column diameter

  • Approximates installed footprint per unit of column base area (clearance, platforms, piping).

    2.2m2/m2
    Footprint factor

  • Represents fraction of light ends recovered and returned to the reactor section after primary separation.

    0.85ratio
    Recycle loop performance assumption

  • Represents screening electricity needed per tonne of recycled light ends compressed/handled.

    35kWh/t
    Compression energy heuristic

  • Installed footprint proxy for compression skids per MW of compressor power.

    80m2/MW
    Plot plan factor

  • Screening net heat duty intensity for solid acid (zeolite) oligomerisation flowsheet.

    0.18MWhth/t
    Technology-specific utility intensity

  • Screening net heat duty intensity for SPA fixed-bed oligomerisation flowsheet.

    0.16MWhth/t
    Technology-specific utility intensity

  • Screening net heat duty intensity for nickel-based oligomerisation flowsheet.

    0.2MWhth/t
    Technology-specific utility intensity

  • Screening electricity intensity for zeolite fixed-bed oligomerisation including recycle compression and auxiliaries (lumped).

    70kWh/t
    Technology-specific utility intensity

  • Screening electricity intensity for SPA fixed-bed oligomerisation (lumped).

    60kWh/t
    Technology-specific utility intensity

  • Screening electricity intensity for Ni-based oligomerisation (lumped).

    85kWh/t
    Technology-specific utility intensity

  • Reference purchased-equipment CAPEX at the reference capacity for zeolite fixed-bed oligomerisation.

    32000000EUR
    Reference equipment purchase cost

  • Reference purchased-equipment CAPEX at the reference capacity for SPA fixed-bed oligomerisation.

    28000000EUR
    Reference equipment purchase cost

  • Reference purchased-equipment CAPEX at the reference capacity for Ni-based oligomerisation.

    35000000EUR
    Reference equipment purchase cost

  • Represents annual fixed O&M as a fraction of equipment purchase CAPEX for tech 1.

    0.04ratio
    Reference fixed O&M fraction

  • Represents annual fixed O&M as a fraction of equipment purchase CAPEX for tech 2.

    0.038ratio
    Reference fixed O&M fraction

  • Represents annual fixed O&M as a fraction of equipment purchase CAPEX for tech 3.

    0.045ratio
    Reference fixed O&M fraction

  • Allocates total equipment purchase CAPEX to the reactor section (reactors, catalyst handling).

    0.35ratio
    Cost breakdown assumption

  • Allocates total equipment purchase CAPEX to separation equipment (columns, exchangers).

    0.3ratio
    Cost breakdown assumption

  • Allocates total equipment purchase CAPEX to recycle compression and related rotating equipment.

    0.15ratio
    Cost breakdown assumption

  • Allocates remaining total equipment purchase CAPEX to auxiliaries (pumps, small exchangers, control skids).

    0.2ratio
    Cost breakdown assumption

  • Used to convert catalyst bed volume proxy to catalyst mass inventory for replacement costing.

    800kg/m3
    Catalyst property assumption

  • Represents fraction of the geometric reactor volume treated as effective catalyst bulk volume for inventory estimation.

    0.6ratio
    Catalyst loading assumption

  • Provides order-of-magnitude catalyst replacement cost for screening.

    40000EUR/t
    Catalyst cost assumption

  • Annualizes catalyst cost by dividing inventory cost by a periodic replacement interval.

    3year
    Replacement interval assumption

  • Approximate H2 required per kg of jet-range hydrocarbon produced from CO2, using representative hydrocarbon composition (e.g., C12H26).

    0.153kg/kg
    Stoichiometric proxy for e-kerosene

  • Approximate CO2 required per kg of jet-range hydrocarbon produced from CO2, using representative hydrocarbon composition (e.g., C12H26).

    3.105kg/kg
    Stoichiometric proxy for e-kerosene

  • Represents upstream electricity requirement (e.g., H2 production + CO2 capture + intermediate synthesis) per kg fuel, excluding this oligomerisation unit’s electricity which is added separately.

    20kWh/kg
    E-fuels route electricity intensity (upstream)

  • Lower heating value for jet-range hydrocarbons used to convert mass to energy and compute efficiency.

    43MJ/kg
    Fuel property (LHV)