Acetaldehyde Production from Ethylene (Single-Step Process)
Acetaldehyde Production Costs Report | Issue E | Q2 2024
| Report Details |
| 70 kta United States-based plant | Q2 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 assesses the economics of Acetaldehyde production from ethylene in the United States using a typical single-step oxidation process. In this process, ethylene oxidation is carried out by using high purity oxygen.
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) Reaction; (2) Recovery and Purification.
Reaction. In the first section, ethylene and oxygen are fed independently to a vertical ceramic-lined reactor, and ethylene is oxidized to Acetaldehyde in the presence of an aqueous solution of PdCl2 and CuCl2, used as a catalyst. The reaction is conducted at 130 °C, and about 3-4 bar. A solution containing the catalyst and Acetaldehyde formed is partially vaporized in the reactor itself and then routed to a separator, in which the Acetaldehyde-water vapor mixture is separated overhead and directed to distillation steps downstream. The catalyst solution withdrawn from the separator bottom, is returned to the reactor, after part of the catalyst being regenerated.
Recovery and Purification. The Acetaldehyde-water vapor mixture from the separator is cooled and scrubbed with process water for the condensation and recovery of Acetaldehyde at the bottom. A large part of the gas leaving the Scrubbing System is recycled to the reactor, but a small part needs to be purged. The purged gas is led to a burner for energy generation. Crude Acetaldehyde recovered at the bottom has a low concentration and needs to be directed to the Purification System, where, after passing through two distillation columns, high-purity Acetaldehyde is obtained. In the first column, low-boiling substances are stripped off and burned for energy generation, while the Acetaldehyde stream obtained as column’s bottom is fed to the second column. In this column, water and higher-boiling by-products are removed. High-purity Acetaldehyde is drawn from the column overhead, condensed, and obtained as the main product.
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Production Process Information
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Operating Cost Details
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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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