Production Cost Report
ICC - Is Bespoken: 0
ICC - Main References: ?
ICC - Issue: B
ICC - Volume: 28
ICC - Report ID: 028-B
ICC - Report Location: United States
ICC - Is Popular: 0
ICC - Is Developed: 1
ICC - Title: Butyl Acrylate Production from Propylene and Butanol
ICC - Show Overview: 1
ICC - Report Location ID: 1
ICC - Plant Capacity Unit ID: 14
ICC - Volume Reports List: 028-A
ICC - Related Reports List: 009-B,009-A
ICC - Report Location Code: USA
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ICC - Prices: {"versions":{"1":{"1":"1199","2":"1199","3":"1199"},"2":{"1":"1999","2":"1999","3":"1999"},"3":{"1":"3399","2":"3399","3":"3399"}},"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-B.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>CG Propylene</b>. Propylene, the main raw material consumed, is a colorless gas at room temperature. It is a low-boiling, flammable, and highly volatile gas. Propylene reacts vigorously with oxidizing materials. The primary hazard associated with propylene is its flammability - precautions must be taken to avoid fire hazards in the handling of the gas. Propylene has been mainly produced as ethylene manufacturing co-product (via steam cracking of paraffinic hydrocarbons) and by-product of petroleum refining (separation from refinery gas). Most recently, amid a tight propylene market, novel lower-cost chemical processes for on-purpose propylene production have emerged.</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-B.jpg
ICC - Process Schematic Text: <p>The process under analysis comprises four major sections: (1) Reaction and quench; (2) Acrylic Acid recovery; (3) Esterification; and (4) Product Purification.</p><p>Reaction and quench. Chemical grade (CG) propylene mixed with steam and air is fed to a two-step oxidation reaction system. Firstly, propylene is oxidized to acrolein, which is then oxidized to acrylic acid. The effluent is sent to a quench tower, where the acrylic acid formed is absorbed in water. This solution is sent to next section. Part of the residual gas from the top of the quench tower is recycled to the first reactor, and the remainder is incinerated. </p><p>Acrylic acid recovery. The acrylic acid solution from quench is purified by extraction with an organic solvent and distillation, removing water, light and heavy ends.</p><p>Esterification. Acrylic acid and a small excess of n-butanol are fed to reaction system. In addition, water is continuously removed from reaction system. The esterification reaction is carried out in two consecutive reactors - the second one equipped with a column for water removal. An organic acid (e.g. benzene sulfonic acid) is employed as catalyst. Yields of 95-98% based on acrylic acid are achieved.</p><p>Product Purification. The reactor effluent, a mixture containing Butyl Acrylate, unreacted butanol, water and some acrylic acid, is passed through a series of columns. Initially, most of acrylic acid is removed from the product stream. This phase is washed to remove butanol and traces of acid. Then, the washed butyl acrylate is dried and further purified in two columns, which separates residual butanol and organic heavy wastes.</p><p></p>
ICC - Short Description: 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.
ICC - Main Product: Butyl Acrylate
ICC - Plant Capacity: 150.00
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Butyl Acrylate Production from Propylene and Butanol

Butyl Acrylate Production Costs Report | Issue B | Q2 2024

Production Cost Report

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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.

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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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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.

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Other Related 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.

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