Acrylic Acid Production from Glycerol
Acrylic Acid Production Costs Report | Issue B | Q2 2024
Report Details |
100 kta United States-based plant | Q2 2024 | 107 pages |
This report presents a cost analysis of a 100 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
It presents the economics of Ester-Grade Acrylic Acid (EAA) production from crude glycerol in the USA using a two-step process similar to Arkema technology. In the process examined, crude glycerol, obtained from biodiesel plants, is dehydrated to acrolein, which is subsequently oxidized to Acrylic Acid.
The report provides a comprehensive study of Acrylic Acid production and related Acrylic Acid production cost, covering three key aspects: a complete description of the Acrylic Acid production process examined; an in-depth analysis of the related Acrylic Acid plant capital cost (Capex); and an evaluation of the respective Acrylic Acid plant operating costs (Opex).
The Acrylic 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 Acrylic 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 Acrylic 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) Crude Glycerol Treatment; (2) Reactions; and (3) Acrylic Acid Recovery.
Crude Glycerol Treatment. Initially, the crude glycerol stream is first mixed with a surfactant to precipitate soaps dissolved in the glycerol, then it is fed to an oil-water separator to remove free oils that might be contaminating the glycerol. The main stream is centrifuged and fed to an ion exchanger vessel, where dissolved salts precipitate. The glycerol is sent to a distillation column, where dissolved lighters and heavier contaminants are separated
Reactions. In the first reaction, glycerol is dehydrated to acrolein in the presence of a solid Bronsted acid catalyst, like tungsten oxide/zirconium oxide. Air is also added to the system to provide oxygen to the reaction medium. The presence of oxygen decreases coke formation in the catalyst and increases the reaction yield. Water and heavy by-products produced in the first reaction are removed in an absorption column to increase acrolein partial pressure in the second reaction, thus increasing its yield and selectivity for acrylic acid. In the second reaction, acrolein conversion takes place in the presence of molybdenum vanadium oxides catalysts.
Acrylic Acid Recovery. Since acrylic acid may spontaneously polymerize when subject to high temperatures, the columns of acrylic acid recovery section are fed with polymerization inhibitors and operated at or below atmospheric pressure to allow low bottom temperatures. The acrylic acid, absorbed in water, is quenched and purified by extraction with an organic solvent and distillation to remove the solvent. The crude acrylic acid stream is directed to another two columns, where first light ends are stripped off and acrylic dimers are removed. The last column overhead, consisting of high purity ester-grade acrylic acid, is condensed and stored.
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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 Acrylic 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 Acrylic 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 Acrylic 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 Acrylic 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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Acrylic Acid Production from Natural Gas
This report presents the economics of Ester-Grade Acrylic Acid (EAA) production from natural gas in the United States. Initially, methane in the natural gas feed is cracked to acetylene which is reacted carbon monoxide generated by feed combustion, yielding Acrylic Acid.
Details: 150 kta United States-based plant | Q2 2024 | 107 pages | Issue K From $1,199 USD
The cost analyses presented in this report target a 150 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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Butyl Acrylate Production from Acrylic Acid and Butanol
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