Caprolactam Production from Phenol
Caprolactam Production Costs Report | Issue E | Q3 2024
| Report Details |
| 180 kta United States-based plant | Q3 2024 | 107 pages |
This report presents a cost analysis of a 180 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 feasibility study examines the economics of a process producing Caprolactam from phenol located in the United States. Initially, phenol is hydrogenated to form cyclohexanone. The cyclohexanone is then submitted to an oximation reaction with hydroxylamine. Finally, the cyclohexanone oxime produced is converted to caprolactam by Beckmann rearrangement.
The report provides a comprehensive study of Caprolactam production and related Caprolactam production cost, covering three key aspects: a complete description of the Caprolactam production process examined; an in-depth analysis of the related Caprolactam plant capital cost (Capex); and an evaluation of the respective Caprolactam plant operating costs (Opex).
The Caprolactam 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 Caprolactam 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 Caprolactam 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 4 major sections: (1) Cyclohexanone production; (2) Oximation & Beckmann rearrangement; (3) Caprolactam purification; and (4) Ammonium sulfate recovery.
Cyclohexanone production. Fresh phenol is distilled, removing heavy impurities. It is fed to stirred reactors operating in series with compressed hydrogen. The reaction takes place in the liquid phase, catalyzed by palladium on carbon, yielding cyclohexanone. Purified cyclohexanone is obtained after the reactor outlet is passed through centrifugation and distillation steps.
Oximation & Beckmann rearrangement. Ammonia is oxidized yielding nitric oxide, which is absorbed in water and then hydrogenated over a palladium catalyst, in the presence of dilute sulfuric acid, producing hydroxylammonium sulfate solution. The hydroxylammonium sulfate solution reacts with purified cyclohexanone in stirred reactors, in toluene solvent, to form cyclohexanone oxime. The solution containing cyclohexanone oxime is then distilled for the removal of toluene solvent. Finally, the cyclohexanone oxime is converted to caprolactam by Beckmann rearrangement, in the presence of oleum.
Caprolactam purification. The product of rearrangement is subjected to purification steps, involving neutralization, extraction in the presence of toluene and light impurities removal. The raw caprolactam melt is transformed into crystals that are melted, solidified on cold surface and the flakes produced are packed and sent to storage facilities.
Ammonium sulfate recovery. Ammonium sulfate solution removed in neutralization steps is concentrated by means of evaporation. Then, it is crystallized, centrifuged and dried.
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Production Process Information
Process Consumptions
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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 Caprolactam 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 Caprolactam 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 Caprolactam 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 Caprolactam 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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Caprolactam from Cyclohexane (Photonitrozation Process)
This report concerns the production of Caprolactam from cyclohexane in the United States. This report reviews a cyclohexane photonitrozation process (PNC). Initially, cyclohexane is submitted to PNC with nitrosyl chloride. The oxime produced is then subjected to Beckmann rearrangement and Caprolactam is formed.
Details: 180 kta United States-based plant | Q3 2024 | 107 pages | Issue F From $1,499 USD
The cost analyses presented in this report target a 180 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.
Caprolactam Production from Toluene
This study reviews the economics of a process for Caprolactam production from toluene. Initially, toluene is oxidized to benzoic acid, which is then hydrogenated to hexahydrobenzoic acid. The hexahydrobenzoic acid is reacted with nitrosyl sulfuric acid and oleum for caprolactam production. The economic analysis performed is based on a plant constructed in the United States.
Details: 180 kta United States-based plant | Q3 2024 | 107 pages | Issue G From $1,499 USD
The cost analyses presented in this report target a 180 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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