Butanol Production from Butyraldehyde
Butanol Production Costs Report | Issue E | Q4 2024
| Report Details |
| 160 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 160 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 analyzes the costs for n-Butanol production from butyraldehyde. In this process, n-butyraldehyde is hydrogenated generating n-Butanol. The economic analysis is based on a plant constructed in the United States.
The report provides a comprehensive study of Butanol production and related Butanol production cost, covering three key aspects: a complete description of the Butanol production process examined; an in-depth analysis of the related Butanol plant capital cost (Capex); and an evaluation of the respective Butanol plant operating costs (Opex).
The Butanol 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 Butanol 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 Butanol 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 Overview
Product
Butanol. n-Butyl Alcohol, also called n-Butanol, is an aliphatic alcohol applied in the production of butyl acrylates. It may be found as compound in nature or in fusel oils obtained via fermentation. Like all butanols. it is a colorless, clear liquid at room temperature and atmospheric pressure. This alcohol is employed as solvent, as well as in plasticizers. The industrial production of n-butanol started in the first decades of the 20th century and was based on a fermentation route that also yielded acetone. Currently, its commercial production is mainly based on the hydrogenation of n-butyraldehyde obtained by the hydroformylation of propylene using synthesis gas (this route is usually called OXO process).
Raw Materials
Hydrogen. The hydrogen molecule, H2, is the normal state of pure hydrogen, even though hydrogen can be found in its atomic form under specific conditions. It is a very stable molecule, not usually reactive under normal conditions. Essentially, molecular hydrogen is produced industrially by three different methods: hydrocarbons steam reforming, hydrocarbons partial oxidation and water electrolysis. Hydrogen can also be obtained as a by-product recovered in processes such as the manufacture of styrene from ethylbenzene.
n-Butyraldehyde. n-Butyraldehyde is an organic compound used as an intermediate in the production of plasticizers, solvents, and rubber accelerators. It is prized for its ability to undergo further reactions in chemical synthesis. n-Butyraldehyde is produced via the hydroformylation of propylene and stored as a liquid. Its reactivity and use in producing chemicals for plastics and rubber make it valuable to the chemical industry.
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Production Process Information
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Production Process Information
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Production Costs Datasheet
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Operating Cost Details
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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 Butanol 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 Butanol 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 Butanol 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 Butanol 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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Bio-Butanol Production from Corn
This report presents the economics of bio-based Butanol production from corn in the United States. The process under analysis is a conventional Acetone-Butanol-Ethanol (ABE) fermentation process. Initially, corn undergoes wet milling to separate starch, which is hydrolyzed in two steps. Glucose is fermented to produce butanol, acetone and ethanol.
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The cost analyses presented in this report target a 90 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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