Dimethyl Carbonate Production from Methanol
Dimethyl Carbonate Production Costs Report | Issue A | Q3 2024
| Report Details |
| 100 kta United States-based plant | Q3 2024 | 107 pages |
This report presents a cost analysis of a 100 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 presents the economics of a non-phosgene process for Dimethyl Carbonate (DMC) production from methanol in the United States. This process is a typical oxidative carbonylation process. Methanol, carbon monoxide and oxygen are reacted in the presence of copper chloride catalyst to yield DMC and water.
The report provides a comprehensive study of Dimethyl Carbonate production and related Dimethyl Carbonate production cost, covering three key aspects: a complete description of the Dimethyl Carbonate production process examined; an in-depth analysis of the related Dimethyl Carbonate plant capital cost (Capex); and an evaluation of the respective Dimethyl Carbonate plant operating costs (Opex).
The Dimethyl Carbonate 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 Dimethyl Carbonate 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 Dimethyl Carbonate 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 three major sections: (1) Reactors Train; (2) Off-gases Treatment; and (3) Purification.
Reactors Train. This section of the plant is composed of two reactors in series, a partial condenser and a knock out drum. CO, O2 and methanol react, in the presence of copper chloride (CuCI) as the catalyst, to form Dimethyl Carbonate (DMC). Each reactor is comprised of two tall vertical cylindrical tubes connected to each other at the top and bottom. Compressed CO and O2 are fed at the bottom of one vessel so the more dense gas-poor liquid phase circulates from the second tube to the first one. The circulation also provides the required agitation for mixing the liquids, enabling the reaction to occur. The gas-phase is withdrawn from the top of the first reactor and fed to the bottom of the first tube of the second reactor, which is also fed with fresh and recycled liquid methanol.
Off-gases Treatment. The off-gases generated along the process are treated to remove organic compounds such as chloroformates, DMC and methanol, which sent back to solid-liquid separation. The gaseous mixture of carbon oxides is washed with an aqueous piperazine activated MDEA solution for the removal of CO2. The CO2 removed is routed to an integrated unit that converts CO2 to CO. Carbon monoxide is compressed and recycled to the reactors.
Purification. The reaction product is withdrawn from the second reactor as a gaseous stream through a cyclone. This stream is then led to a partial condenser that generates a DMC-rich liquid stream and a gaseous stream containing mostly CO and CO2. The liquid portion of the reaction product is fed to a flash drum, which reduces the pressure at nearly atmosphere. A gaseous stream comprising any residual gases and volatile organics is generated. The liquid phase is treated for recovery of residual catalyst and acid compounds, and then subjected to distillation operations that first recover unreacted methanol as a methanol/DMC azeotrope - that is recycled to reaction - and then separate a DMC/water azeotropic mixture into a wastewater stream and purified DMC product with purity higher than 99.8 wt%.
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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 Dimethyl Carbonate 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 Dimethyl Carbonate 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 Dimethyl Carbonate 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 Dimethyl Carbonate 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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