Acrylonitrile Production from Propane
Acrylonitrile Production Costs Report | Issue B | Q2 2024
Report Details |
200 kta United States-based plant | Q2 2024 | 107 pages |
This report presents a cost analysis of a 200 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 study presents the economics of Acrylonitrile production via propane ammoxidation. The process is similar to the one proposed by PTT Asahi Chemical (PTTAC), consisting in the reaction of propane with ammonia, producing Acrylonitrile. Acetonitrile and hydrogen cyanide are produced as by-products. The analysis assumes a plant located in the United States,
The report provides a comprehensive study of Acrylonitrile production and related Acrylonitrile production cost, covering three key aspects: a complete description of the Acrylonitrile production process examined; an in-depth analysis of the related Acrylonitrile plant capital cost (Capex); and an evaluation of the respective Acrylonitrile plant operating costs (Opex).
The Acrylonitrile 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 Acrylonitrile 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 Acrylonitrile 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 four major sections: (1) Reaction; (2) Separation; (3) Acetonitrile recovery; and (4) Purifcation.
Reaction. Ammonia is mixed with compressed air and propane in vapor phase. The gaseous feed is preheated and fed to a fluid-bed reactor. The reaction product comprises Acrylonitrile, hydrogen cyanide, acetonitrile, carbon oxides, aldehydes, as well as unconverted propane and ammonia.
Separation. The reaction product is quenched with a sulfuric acid solution for ammonia neutralization. The quench column liquid product comprises an ammonium sulfate solution, which is further treated for generating ammonium sulfate by-product. The gaseous stream from this column is fed to an absorber, where Acrylonitrile is absorbed and transferred to the recovery column. In the recovery column, acetonitrile and water are separated from Acrylonitrile and hydrogen cyanide.
Acetonitrile recovery. A liquid side stream from the recovery column, containing a mixture of acetonitrile and water, is sent to the acetonitrile stripper, where the it is distilled under vacuum to separate water and heavy organics. The acetonitrile-water azeotrope obtained is then distilled at high pressure into three streams: a bottom product comprising heavy impurities; an aqueous stream containing also some acetonitrile as column overhead, which is recycled to the acetronitrile stripper; and a side stream containing high-purity acetonitrile.
Products Separation. The organic phase from the recovery column, containing Acrylonitrile, hydrogen cyanide and aldehyde impurities, is fed to an agitated vessel, where aldehyde impurities are converted into cyanohydrins, which boil at significantly higher temperatures than the Acrylonitrile product and can be more easily separated from Acrylonitrile by distillation. The Acrylonitrile-rich stream is further treated in two distillation columns. In the first column, hydrogen cyanide is obtained as the overheads product. Fiber-grade Acrylonitrile product is finally withdrawn from a side-draw in the second column.
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Production Process Information
Process Consumptions
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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 Acrylonitrile 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 Acrylonitrile 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 Acrylonitrile 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 Acrylonitrile 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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