Glacial Acrylic Acid from Crude Acrylic Acid (Crystallization)
Acrylic Acid Production Costs Report | Issue H | Q4 2024
| Report Details |
| 140 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 140 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 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.
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 two major sections: (1) Dynamic Crystallization; and (2) Static Crystallization.
Dynamic Crystallization. Fresh ester grade acrylic acid is routed, along with purified acrylic acid from Static Crystallization downstream, to falling film crystallizers. The falling film crystallizers consist in systems of vertical tubes, in which the Acrylic Acid flows down on the inside surface of the tubes while the cooling/heating media is distributed to wet the external surface of the tubes. Crystallization is carried out in multiple stages. The outlet from the last stage comprises purified Acrylic Acid with 99.7 wt% purity. The residue is directed to the Static Crystallization.
Static Crystallization. The residue from the Dynamic Crystallization is sent to the residue adjustment tank, where water is used to dissolve impurities and prevent precipitation in further crystallization steps. The residue is then fed to a series of static melt crystallizers. As the crystal layer is formed in each stage, the melt is drained off and routed to a downstream stage, and sweating is induced. The sweated fraction is removed, and the remaining crystal layer is melted and routed to the subsequent stage. Finally, the purified Acrylic Acid from the last stage is recycled to the Dynamic Crystallizers. The residue is burned as fuel.
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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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