Acetaldehyde Production from Acetylene (Vapor-Phase Hydration)
Acetaldehyde Production Costs Report | Issue D | Q3 2024
| Report Details |
| 70 kta United States-based plant | Q3 2024 | 107 pages |
This report presents a cost analysis of a 70 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 report approaches the economics of an acetylene hydration process in the United States. In this study, hydration is carried out in vapor phase with steam over a solid catalyst.
The report provides a comprehensive study of Acetaldehyde production and related Acetaldehyde production cost, covering three key aspects: a complete description of the Acetaldehyde production process examined; an in-depth analysis of the related Acetaldehyde plant capital cost (Capex); and an evaluation of the respective Acetaldehyde plant operating costs (Opex).
The Acetaldehyde 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 Acetaldehyde 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 Acetaldehyde 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 two major sections: (1) Hydration; and (2) Purification.
Hydration. Acetylene and excess steam are heated to reaction temperature and fed to vertical reactor tubes operating alternatively, where the feed contacts catalyst at 350-400 °C. The reactors are arranged in such a way that while three reactors are actually operating, one is in catalyst regeneration cycle. The reaction medium is passed successively through three reactors, with fresh feed mixture and steam being fed to each of them; while the reaction is highly exothermic, quench water is employed for cooling each reactor effluent back to the desired reaction temperature. At the end, about 65% of the acetylene in the mixture react, with 90-95% of the reacted acetylene being converted to acetaldehyde.
Purification. The gaseous stream from the reactors, comprising ethylene, some unreacted acetylene, acetaldehyde product, and steam, is cooled and fed to a flash vessel, where heavy reaction by-products are removed and discarded, most of the water is recovered and recycled for quenching reactors effluents. The crude Acetaldehyde stream is further purified by distillation; the unreacted acetylene and remaining water are recycled.
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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 Acetaldehyde 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 Acetaldehyde 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 Acetaldehyde 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 Acetaldehyde 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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