Cyclohexanone Production from Phenol
Cyclohexanone Production Costs Report | Issue B | Q4 2024
| Report Details |
| 160 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 160 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 economics of producing Cyclohexanone from phenol. In the examined process, phenol undergoes a hydrogenation reaction in the liquid phase, in the presence of a palladium-based catalyst, yielding Cyclohexanone. The analysis is based on a plant located in the United States.
The report provides a comprehensive study of Cyclohexanone production and related Cyclohexanone production cost, covering three key aspects: a complete description of the Cyclohexanone production process examined; an in-depth analysis of the related Cyclohexanone plant capital cost (Capex); and an evaluation of the respective Cyclohexanone plant operating costs (Opex).
The Cyclohexanone 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 Cyclohexanone 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 Cyclohexanone 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 is comprised of three main sections: (1) Phenol Purification; (2) Hydrogenation and (3) Cyclohexanone Purification.
Phenol Purification. First fresh phenol is contacted with a solution of caustic soda and a sequestrating agent to remove metallic impurities that would be detrimental for the hydrogenation catalyst. This phenol mixture is then subjected to a two-step distillation system, producing a purified phenol stream that is directed to the hydrogenation reactor and a heavies waste stream.
Hydrogenation. Fresh hydrogen is first compressed to the hydrogenation reaction pressure and then fed to the first hydrogenation reactor alongside the purified phenol stream from the purification section. The hydrogenation is conducted in three reactors in series, in liquid phase, at mild pressure and catalyzed by palladium supported on carbon. Hydrogen is fed in excess to ensure maximum conversion of the phenol. The off-gas from the reactor is then sent to a scrubber where it is contacted against water before its disposal.
Cyclohexanone Purification. The liquid output from the hydrogenation reactors is first sent to centrifuges that are going to separate a cyclohexanone-rich liquid phase, from a the solid catalyst, that is in turn recycled to the hydrogenation reactors. The liquid stream is then subjected to a final distillation step that aims to remove traces of cyclohexanol and other heavier byproduct contaminants from the product stream. Purified Cyclohexanone is recovered as the top product of the distillation column.
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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 Cyclohexanone 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 Cyclohexanone 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 Cyclohexanone 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 Cyclohexanone 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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This report presents the economics of Cyclohexanone production from cyclohexane for a plant located in the United States. The process examined involves two main steps: (1) liquid-phase air oxidation of cyclohexane to a mixture of cyclohexanone and cyclohexanol; and (2) cyclohexanol dehydrogenation for further generation of cyclohexanone.
Details: 160 kta United States-based plant | Q4 2024 | 107 pages | Issue A From $799 USD
The cost analyses presented in this report target a 160 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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