Production Cost Report
ICC - Is Bespoken: 0
ICC - Main References: ?
ICC - Issue: A
ICC - Volume: 9
ICC - Report ID: 009-A
ICC - Report Location: United States
ICC - Is Popular: 0
ICC - Is Developed: 1
ICC - Title: Butanol Production from Ethanol
ICC - Show Overview: 1
ICC - Report Location ID: 1
ICC - Plant Capacity Unit ID: 14
ICC - Volume Reports List: 009-A,009-B,009-C,009-D,009-E
ICC - Related Reports List: 241-S,197-B,028-B,241-A
ICC - Report Location Code: USA
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ICC - Plant Capacity Unit Name: kilo metric ton per annum
ICC - Plant Capacity Unit Short Name: kta
ICC - Process Overview Image: //cdn.intratec.us/images/icc/process-overview/009-A.jpg
ICC - Process Overview Text: <h6>Product</h6> <p><b>Butanol</b>. 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).</p> <h6>Raw Materials</h6> <p><b>Chemicals</b>. </p> <b>Ethanol</b>. Ethanol, also known as ethyl alcohol, may work as a solvent, a germicide, a fuel, and as a chemical intermediate for other organic chemicals. Currently, ethanol is mostly produced via fermentation of sugars, which can be obtained from crops, such as sugarcane and starch. However by relying on the sugar and starch content of food crops, ethanol production competes with food production. Therefore, recent research focus on the use of low-value raw materials, often deemed “waste”, to produce ethanol. That low-value feed can be biomass of lignocellulosic material found in wood, sugarcane bagasse and grain crop stubbles, or can be carbon monoxide found in waste gas streams from a range of industries. Lignocellulosic biomass could represent a new fermentable raw material if hydrolysis of this material is performed. Technological advances in this reaction still need to be achieved in order to make it economically feasible and render this usage of the agricultural residues competitive with respect to others, such as heat generation by burn.</p>
ICC - Process Schematic Image: //cdn.intratec.us/images/icc/process-schematics/009-A.jpg
ICC - Process Schematic Text: <p>The process under analysis comprises three major sections: (1) Reaction; (2) Raw Materials Recovery; and (3) Purification.</p><p>Reaction. Fresh anhydrous ethanol is mixed with recycled ethanol and vaporized. Vaporized ethanol is mixed with fresh hydrogen make-up and recycled purified hydrogen from the Pressure Swing Adsorption (PSA) unit. The gaseous mixture is preheated and fed to the reactor, where the exothermic Guerbet reactions take place. The ethanol/hydrogen mixture contacts the catalyst at high temperature and pressure, maximizing n-Butanol yields. Small amounts of by-product alcohols, ethers and esters are also formed in the reaction. The hot reactor product is first cooled and then transferred to a flash vessel, where a gaseous phase forms and is separated from the liquid organic mixture. </p><p>Raw Materials Recovery. The liquid organic mixture from Butanol reactor is first fed to another flash vessel for pressure release. Most of remaining hydrogen vaporizes and is compressed. Compressed hydrogen is sent the PSA Unit with gas from first flash vessel upstream, where it is purified and recycled to reactor. The organic liquid is pumped to a splitter column, where high boiling alcohols are separated from ethanol and water, which are withdrawn from the column as an overhead vapor stream. These vapours are introduced in a column, where ethyl acetate is separated from the ethanol/water mixture. This mixture is passed through a azeotropic distillation with ethylene glycol, in order to separate water from gaseous dry ethanol, which is recycled to reactor.</p><p>Purification. The highers alcohols from the splitter column are fed to another two columns in series. The first separates hexanol and higher alcohols, while the second separates isobutanol and lighter components. Both streams are used as fuel. n-Butanol pure product is finally obtained.</p><p></p>
ICC - Short Description: The report shows an economic analysis of the construction of an industrial plant in the United States for n-Butanol production. In the process reviewed ethanol is dimerized into n-Butanol via the Guerbet reaction. This reaction is composed by dehydrogenation, aldol condensation and hydrogenation.
ICC - Main Product: Butanol
ICC - Plant Capacity: 80.00
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Butanol Production from Ethanol

Butanol Production Costs Report | Issue A | Q2 2024

Production Cost Report

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80 kta United States-based plant   |   Q2 2024   |   107 pages   |   Delivered in PDF

This report presents a cost analysis of a 80 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.

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Production Process Information

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Production Process Information

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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

Other Butanol Production Cost Reports

Butanol Production from Ethanol

The report shows an economic analysis of the construction of an industrial plant in the United States for n-Butanol production. In the process reviewed ethanol is dimerized into n-Butanol via the Guerbet reaction. This reaction is composed by dehydrogenation, aldol condensation and hydrogenation.

Details: 80 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue A   From $799 USD

The cost analyses presented in this report target a 80 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.

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.

Details: 90 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue B   From $799 USD

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.

Bio-Butanol Production from Raw Sugar

This report examines a conventional Acetone-Butanol-Ethanol (ABE) fermentation process. This economic analysis assumes a plant located in Germany using raw sugar as feedstock, which is fermented to Butanol, acetone and ethanol by a novel strain of Clostridium. Each product is separated.

Details: 90 kta Germany-based plant   |   Q2 2024   |   107 pages   |   Issue C   From $999 USD

The cost analyses presented in this report target a 90 kta (kilo metric ton per annum per annum) Germany-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

Butanol Production from Propylene and Syngas

This report presents an economic analysis of n-Butanol production from propylene and syngas, assuming a plant located in the United States. The process under analysis is similar to the LP OXO technology jointly licensed by JM Davy and Dow, employing Selector 30 catalyst. This process comprises hydroformylation of propylene and n-butyraldehyde hydrogenation.

Details: 120 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue D   From $799 USD

The cost analyses presented in this report target a 120 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.

Butanol Production from Butyraldehyde

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.

Details: 160 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue E   From $799 USD

The cost analyses presented in this report target a 160 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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Other Related Production Cost Reports

Butyl Acrylate Production from Propylene and Butanol

This study concerns the production of n-Butyl Acrylate, starting from propylene and n-butanol. Chemical grade propylene is oxidized to acrolein and then to acrylic acid, which is then fed to an esterification reaction, along with n-butanol to generate Butyl Acrylate. The economic analysis performed is based on a plant located in the United States.

Details: 150 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue B   From $1,199 USD

The cost analyses presented in this report target a 150 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.

Hexamethylene Diisocyanate from HMDA (Non-Phosgene Process)

This report presents a techno-economic analysis of Hexamethylene Diisocyanate (HDI) production from hexamethylene diamine (HMDA) in the United States. The process presented in this report is a non-phosgene process similar to BASF process. Initially, HMDA reacts with urea and butanol generating a carbamate intermediate. Then, the carbamate is thermally cracked producing HDI.

Details: 20 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue B   From $799 USD

The cost analyses presented in this report target a 20 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.

Cellulosic Ethanol from Corn Stover (Ammonia Conditioning)

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Details: 200 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue A   From $799 USD

The cost analyses presented in this report target a 200 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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This report presents the economics of Anhydrous Ethanol production from wood chips in the United States. In the process examined, wood feedstock is submitted to direct gasification, producing synthesis gas. Next, the syngas is converted to mixed alcohols. The alcohol mixture is then distilled, yielding ethanol and a mixture of higher molecular weight alcohols.

Details: 100 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue S   From $799 USD

The cost analyses presented in this report target a 100 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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