Butyl Acrylate Production from Acrylic Acid and Butanol
Butyl Acrylate Production Costs Report | Issue A | Q2 2024
| Report Details |
| 150 kta United States-based plant | Q2 2024 | 107 pages |
This report presents a cost analysis of a 150 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 approaches the production of n-Butyl Acrylate from acrylic acid and n-butanol. The process examined is similar to the Synthomer's Butyl Acrylate Process. In this process acrylic acid and n-butanol are directly converted to Butyl Acrylate via an esterification reaction catalyzed by p-Toluene Sulfonic Acid. The economic analysis performed assumes a plant located in the United States.
The report provides a comprehensive study of Butyl Acrylate production and related Butyl Acrylate production cost, covering three key aspects: a complete description of the Butyl Acrylate production process examined; an in-depth analysis of the related Butyl Acrylate plant capital cost (Capex); and an evaluation of the respective Butyl Acrylate plant operating costs (Opex).
The Butyl Acrylate 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 Butyl Acrylate 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 Butyl Acrylate 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) Esterification; and (2) Purification.
Esterification. In the process under analysis, acrylic acid, a small excess of butanol and p-toluene sulfonic acid catalyst are fed to the reaction system. The esterification reactor is connected to a distillation system for continuous removal of water from the reactor medium, improving reaction kinetics and shifting the reaction toward ester formation. Organic compounds recovered in the bottoms are recycled to the esterification reactor, while water is used as solvent for catalyst extraction.
Purification. Water recovered is fed to a catalyst extraction column to separate catalyst from previously cooled reaction product withdrawn from second reactor. The stream comprising catalyst is recycled to esterification reactor. The crude product is fed to a wash column, where residues of acrylic acid and catalyst are neutralized by means of a caustic solution and separated from the crude product as the column bottom stream. The top stream is distilled to recover butanol, which is sent to dehydration distillation upstream. In the last purification step, a column separates residual organic heavy wastes from the crude Butyl Acrylate stream, yielding high purity Butyl Acrylate as column overhead. The organic heavies are directed to the decomposer reactor, where extra amounts of Butyl Acrylate are recovered by the catalytic reaction of heavy by-products.
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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 Butyl Acrylate 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 Butyl Acrylate 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 Butyl Acrylate 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 Butyl Acrylate 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 Butyl Acrylate 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.
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