Production Cost Report
ICC - Is Bespoken: 0
ICC - Main References: ?
ICC - Issue: A
ICC - Volume: 7
ICC - Report ID: 007-A
ICC - Report Location: United States
ICC - Is Popular: 0
ICC - Is Developed: 1
ICC - Title: Acrylic Acid Production from Propylene
ICC - Show Overview: 1
ICC - Report Location ID: 1
ICC - Plant Capacity Unit ID: 14
ICC - Volume Reports List: 007-B,007-C,007-D,007-E,007-F,007-H,007-K,007-M,007-G,007-I,007-J,007-L
ICC - Related Reports List: 028-A,007-H
ICC - Report Location Code: USA
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ICC - Plant Capacity Unit Name: kilo metric ton per annum
ICC - Plant Capacity Unit Short Name: kta
ICC - Process Overview Image: //cdn.intratec.us/images/icc/process-overview/007-A.jpg
ICC - Process Overview Text: <h6>Product</h6> <p><b>Acrylic Acid</b>. Acrylic acid, ester grade is a vital intermediate in the production of acrylate esters, which are widely used in adhesives, coatings, and textiles. Its reactivity enables it to form polymers that are valuable for water-based paints, adhesives, and textiles. Ester grade acrylic acid is typically produced through the oxidation of propylene. It is stored as a liquid and supplied to manufacturers who use it to create a range of acrylate-based products, driving demand across multiple industries.</p> <h6>Raw Materials</h6> <p><b>Chemicals</b>. </p> <b>CG Propylene</b>. Propylene, the main raw material consumed, is a colorless gas at room temperature. It is a low-boiling, flammable, and highly volatile gas. Propylene reacts vigorously with oxidizing materials. The primary hazard associated with propylene is its flammability - precautions must be taken to avoid fire hazards in the handling of the gas. Propylene has been mainly produced as ethylene manufacturing co-product (via steam cracking of paraffinic hydrocarbons) and by-product of petroleum refining (separation from refinery gas). Most recently, amid a tight propylene market, novel lower-cost chemical processes for on-purpose propylene production have emerged.</p>
ICC - Process Schematic Image: //cdn.intratec.us/images/icc/process-schematics/007-A.jpg
ICC - Process Schematic Text: <p>The process under analysis comprises three major sections: (1) Reaction and quench; (2) Product recovery; and (3) Purification.</p><p>Reaction and quench. Chemical grade (CG) propylene mixed with steam and air is fed to a two-step oxidation reaction system. Firstly, propylene is oxidized to acrolein, which is then oxidized to acrylic acid. The effluent is sent to a quench tower, where the acrylic acid formed is absorbed in water. This solution is sent to product recovery. Part of the residual gas from the top of the quench tower is recycled to the first reactor, and the remainder is incinerated. </p><p>Product recovery. The aqueous solution from quench is fed to an extractor, in which the acrylic acid is separated by means of liquid-liquid extraction with a solvent. The top of the extractor, containing the acrylic acid, is sent to a solvent separation column to recover a two-phase overheads stream. This two-phase stream is separated and the organic phase, containing the solvent, is recycled to the extractor. The aqueous phase is mixed with the raffinate from the extraction step and sent to a solvent stripper to minimize the solvent losses. The bottom stream from solvent recovery column is then fed to the light-ends cut column, where a concentrated acrylic acid stream is obtained as the bottom product. The column overhead stream, mainly comprised of acetic acid and light impurities, is sent to an incinerator. </p><p>Purification. The concentrated acrylic acid from the light-end cut column is fed to the acrylic acid column. In this column, ester-grade acrylic acid is obtained as the overhead product. The column bottoms composed of acrylic acid dimers are sent to the bottoms stripper column, where the heavy ends are separated and sent to waste, while residual acrylic acid is recycled to acrylic acid column.</p><p></p>
ICC - Short Description: This report presents the economics of Ester-Grade Acrylic Acid (EAA) production from chemical grade (CG) propylene in a plant located in the United States. The process consists in a two stage vapor-phase oxidation of propylene, yieding Acrylic Acid, which is then purified to obtain the Ester-Grade product.
ICC - Main Product: Acrylic Acid
ICC - Plant Capacity: 150.00
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Acrylic Acid Production from Propylene

Acrylic Acid Production Costs Report | Issue A | Q2 2024

Production Cost Report

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150 kta United States-based plant   |   Q2 2024   |   107 pages

This report presents a cost analysis of a 150 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.

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Production Process Information

Process Consumptions

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Production Costs Datasheet

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Operating Cost Details

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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

Other Acrylic Acid Production Cost Reports

Glacial Acrylic Acid from Crude Acrylic Acid (Distillation)

This analysis presents the costs associated with the construction of an industrial plant in the United States, for crude acrylic acid purification via distillation to produce Glacial Acrylic Acid.

Details: 120 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue I   From $799 USD

The cost analyses presented in this report target a 120 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.

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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Other Related Production Cost Reports

Glacial Acrylic Acid from Crude Acrylic Acid (Crystallization)

This report presents the costs associated with the construction of an industrial plant, in the United States, for crude acrylic acid purification to produce Glacial Acrylic Acid. The purification process examined is based on crude acrylic acid crystallization.

Details: 140 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue H   From $799 USD

The cost analyses presented in this report target a 140 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.

Butyl Acrylate Production from Acrylic Acid and Butanol

This report approaches the production of n-Butyl Acrylate from acrylic acid and n-butanol. The process examined is similar to the Synthomer's Butyl Acrylate Process. In this process acrylic acid and n-butanol are directly converted to Butyl Acrylate via an esterification reaction catalyzed by p-Toluene Sulfonic Acid. The economic analysis performed assumes a plant located in the United States.

Details: 150 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue A   From $799 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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