Butadiene Production from Carbon Monoxide
Butadiene Production Costs Report | Issue H | Q4 2024
| Report Details |
| 20 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 20 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 1,3-Butadiene production from carbon monoxide in the United States using a process similar to LanzaTech/Invista. First, carbon monoxide (CO) is fermented forming 2,3-butanediol (BDO). Then, BDO is catalytically dehydrogenated to 1,3-Butadiene (BD).
The report provides a comprehensive study of Butadiene production and related Butadiene production cost, covering three key aspects: a complete description of the Butadiene production process examined; an in-depth analysis of the related Butadiene plant capital cost (Capex); and an evaluation of the respective Butadiene plant operating costs (Opex).
The Butadiene 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 Butadiene 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 Butadiene 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) Fermentation; and (2) Butanediol dehydration; and (3) Purification.
Fermentation. The anaerobic fermentation of carbon monoxide is carried out by bacteria, such as the clostridium autoethanogenum. The fermentation can be divided the batch fermentation, and the continuous fermentation. In the batch fermentation, nutrients are fed to a sequence of fermentation vessels, in order to allow microorganisms to multiply until reaching the desired concentration. Once the fermentation vessels contain the minimum cells concentration required for the butanediol fermentation, the continuous fermentation starts. Waste gas and nutrients are continuously supplied, while fermentation broth is removed from the fermenter at a constant mass flow rate. The continuous fermentation produces butanediol and ethanol at butanediol:ethanol ratio of 1:2.
Butanediol dehydration. The fermentation broth is separated from the mixture in a centrifuge and a chromatographic separation comprising an adsorbant. Ethanol is further recovered in a small column as the bottom product. The is then fed to the catalytic dehydration reactor for producing Butadiene. Methyl ethyl ketone (MEK) and 3-buten-2-ol are generated by side reactions.
Purification. The reactor effluent is compressed and directed to a column, where butadiene is recovered under pressure in liquid form as overhead stream. The bottoms product is routed another distillation column and a pressure-swing system to separate MEK from water and other by-products.
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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 Butadiene 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 Butadiene 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 Butadiene 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 Butadiene 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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