Production Cost Report
ICC - Is Bespoken: 0
ICC - Main References: ?
ICC - Issue: A
ICC - Volume: 28
ICC - Report ID: 028-A
ICC - Report Location: United States
ICC - Is Popular: 0
ICC - Is Developed: 1
ICC - Title: Butyl Acrylate Production from Acrylic Acid and Butanol
ICC - Show Overview: 1
ICC - Report Location ID: 1
ICC - Plant Capacity Unit ID: 14
ICC - Volume Reports List: 028-A,028-B
ICC - Related Reports List: 007-B,007-A,009-A,009-B
ICC - Report Location Code: USA
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ICC - Prices: {"versions":{"1":{"1":"799","2":"799","3":"799"},"2":{"1":"1599","2":"1599","3":"1599"},"3":{"1":"2699","2":"2699","3":"2699"}},"currency":"USD"}
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/028-A.jpg
ICC - Process Overview Text: <h6>Product</h6> <p><b>Butyl Acrylate</b>. Butyl Acrylate, the butyl ester of acrylic acid, is one of the main acrylates, along with methyl acrylate and ethyl acrylate. The term acrylates refers to derivatives of acrylic acid and methacrylic acid, such as salts and esters. These compounds were known since the nineteenth century, however only in the 1930s difficulties associated with their production and polymerization were overwhelmed. Over the past decades, acrylates have been building blocks of major importance, widely used in emulsion and solution polymers.</p> <h6>Raw Materials</h6> <p><b>Chemicals</b>. </p> <b>Acrylic Acid</b>. Acrylic acid, ester grade is a vital intermediate in the production of acrylate esters, which are widely used in adhesives, coatings, and textiles. Its reactivity enables it to form polymers that are valuable for water-based paints, adhesives, and textiles. Ester grade acrylic acid is typically produced through the oxidation of propylene. It is stored as a liquid and supplied to manufacturers who use it to create a range of acrylate-based products, driving demand across multiple industries.</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>
ICC - Process Schematic Image: //cdn.intratec.us/images/icc/process-schematics/028-A.jpg
ICC - Process Schematic Text: <p>The process under analysis comprises two major sections: (1) Esterification; and (2) Purification.</p><p>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. </p><p>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.</p>
ICC - Short Description: 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.
ICC - Main Product: Butyl Acrylate
ICC - Plant Capacity: 150.00
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Butyl Acrylate Production from Acrylic Acid and Butanol

Butyl Acrylate Production Costs Report | Issue A | Q2 2024

Production Cost Report

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

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.

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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 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 Acrylic Acid and Butanol

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.

Details: 150 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue A   From $799 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.

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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Other Related Production Cost Reports

Acrylic Acid Production from Propylene

This report presents the economics of Ester-Grade Acrylic Acid (EAA) production from chemical grade (CG) propylene in a plant located in the United States. The process consists in a two stage vapor-phase oxidation of propylene, yieding Acrylic Acid, which is then purified to obtain the Ester-Grade product.

Details: 150 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue A   From $799 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.

Acrylic Acid Production from Glycerol

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Details: 100 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue B   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.

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.

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