Acetic Acid Production from Methanol
Acetic Acid Production Costs Report | Issue B | Q2 2024
Report Details |
650 kta United States-based plant | Q2 2024 | 107 pages | Delivered in PDF |
This report presents a cost analysis of a 650 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 feasibility study refers to Acetic Acid production from methanol and carbon monoxide in the United States using a typical rhodium-catalyzed carbonylation process.
The report provides a comprehensive study of Acetic Acid production and related Acetic Acid production cost, covering three key aspects: a complete description of the Acetic Acid production process examined; an in-depth analysis of the related Acetic Acid plant capital cost (Capex); and an evaluation of the respective Acetic Acid plant operating costs (Opex).
The Acetic Acid 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 Acetic Acid 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 Acetic Acid 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 three major sections: (1) Catalyst Preparation; (2) Carbonylation; and (3) Purification.
Catalyst Preparation. Initially, recycled rhodium catalyst is treated to recover the rhodium. The treated catalyst is mixed with fresh catalyst, promoter (methyl iodide) and stabilizer (iodide salt) and dissolved in hot acetic acid under carbon monoxide pressure.
Carbonylation. The reactor is fed with methanol, recycle streams, the catalyst solution and carbon monoxide. The reaction occurs in the liquid phase, where dissolved carbon monoxide is combined with methanol yielding Acetic Acid. Gases vented from the reactor are cooled to recover methanol, methyl iodide and methyl acetate. Uncondensables are sent to the methanol scrubber, to prevent loss of low boiling components such as methyl iodide. Liquid product is drawn off from the carbonylation reactor at a rate sufficient to maintain a constant level, and fed to a flash vessel where the catalyst solution is withdrawn as a base stream. The product overhead of the flash vessel, a crude Acetic Acid stream containing methyl iodide, methyl acetate, and water (up to 6 wt%), is sent to purification columns.
Purification. The crude Acetic Acid stream is purified in distillation columns, yielding glacial Acetic Acid product. Methyl iodide, methyl acetate, and water recovered in the purification steps are returned to the process.
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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 Acetic Acid 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 Acetic Acid 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 Acetic Acid 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 Acetic Acid 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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The cost analyses presented in this report target a 650 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.
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