Adipic Acid Production from KA Oil
Adipic Acid Production Costs Report | Issue J | Q4 2024
| Report Details |
| 350 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 350 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 economics of Adipic Acid production from a mixture of cyclohexanone and cyclohexanol (known as KA oil) in the United States. The process portrayed comprises the oxidation of the KA oil with nitric acid to produce Adipic Acid. A mixture of adipic, glutaric, and succinic acids is generated as by-product.
The report provides a comprehensive study of Adipic Acid production and related Adipic Acid production cost, covering three key aspects: a complete description of the Adipic Acid production process examined; an in-depth analysis of the related Adipic Acid plant capital cost (Capex); and an evaluation of the respective Adipic Acid plant operating costs (Opex).
The Adipic 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 Adipic 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 Adipic 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) KA Oxidation and (2) AA Crystallization and AGS Recovery.
KA Oxidation. The KA oil is oxidized with nitric acid in the presence of a copper/vanadium catalyst to form Adipic Acid. The oxidation reaction is extremely quick and carried out in two converters, operating at different temperatures. Nitrogen oxides and nitrogen gas are released from the reaction. While this can be viewed as nitric acid losses, NO2 and NO gases are recovered and recycled as nitric acid after an absorption step and a N2O abatement. The product generated from KA oil oxidation goes through bleaching, sending more gases to the absorber. The resulting liquid undergoes a concentration step to separate water and monobasic acids by vacuum stripping. The concentrated solution is subsequently sent to the crystallization process.
AA Crystallization and AGS Recovery. Crude Adipic Acid is obtained after a crystallization step under vacuum followed by centrifugation. This product is then re-dissolved in water, recrystallized, centrifuged, and dried, yielding pure fiber-grade Adipic Acid. Some of the mother liquor from the first centrifugation process is recycled into the KA oil converters. The remaining portion, along with the liquor generated after the second centrifugation, is treated to recover the catalysts, more nitric acid - recycled into the process - and an aqueous mixture containing adipic, glutaric, and succinic acids. This mixture is stored and later commercialized as a Liquid AGS mixture.
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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 Adipic 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 Adipic 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 Adipic 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 Adipic 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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