Butanol Production from Propylene and Syngas
Butanol Production Costs Report | Issue D | Q4 2024
| Report Details |
| 120 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 120 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 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.
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 Schematic
The process under analysis comprises the following major sections: (1) hydroformylation; (2) butyraldehyde separation; (3) hydrogenation; and (4) Butanol purification.
Hydroformylation. Fresh propylene, syngas, recycled reactants, and recycled catalyst solution are fed to the first of two reactors operating in series. In both reactors, the propylene reacts with carbon monoxide and hydrogen at mild temperatures and low pressures, yielding n-butyraldehyde and isobutyraldehyde. The liquid effluent from the hydroformylation, containing catalyst components, reaction products, unreacted propylene, as well as aldehyde products with some dissolved gases, is depressurized and fed to a falling-film evaporator. The concentrated catalyst solution obtained from the evaporator is recycled to hydroformylation. The vapor from the evaporator is partially condensed and the uncondensed gas is recycled to the reactor through a compressor. The condensed liquid stream is sent to the butyraldehyde separation.
Butyraldehyde Separation. The condensed liquid stream from the catalyst recovery is fed to a Stabilizer, for the removal of the remaining traces of dissolved gases. The aldehyde stream is sent to the butyraldehydes splitter, where isobutyraldehyde is separated. The stream rich in n-butyraldehyde is routed to the n-butyraldehyde column, which further purifies the n-butyraldehyde from heavy impurities.
Hydrogenation. The n-butyraldehyde is charged into a hydrogenation reactor where it is reacted with hydrogen, yielding mainly n-Butanol.
Butanol Purification. The liquid stream from the hydrogenation is directed to the first of two distillation columns for the purification of n-Butanol product. In the first column, light-ends are removed and heavy impurities are removed in a second distillation column. The final product obtained is n-Butanol with 99.5 wt% purity.
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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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