FDCA Production from Glucose
FDCA Production Costs Report | Issue A | Q4 2024
| Report Details |
| 270 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 270 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 2,5-Furandicarboxylic Acid (FDCA) production from glucose syrup via a furan process similar to Avantium YXY technology. Initially, glucose is enzymatically isomerized into fructose, which is dehydrated in the presence of methanol, yielding methoxymethylfurfural (MMF). Finally, MMF is oxidized to FDCA. The economic analysis assumes a plant constructed in the United States.
The report provides a comprehensive study of FDCA production and related FDCA production cost, covering three key aspects: a complete description of the FDCA production process examined; an in-depth analysis of the related FDCA plant capital cost (Capex); and an evaluation of the respective FDCA plant operating costs (Opex).
The FDCA 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 FDCA 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 FDCA 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) Furans Production; (2) MMF Purification; and (3) FDCA Production.
Furans production. The glucose content of the feed is first enzymatically isomerized to fructose, and the effluent is passed through ion-exchange resins to separate unreacted glucose from the fructose. The former is recycled to the isomerization reactor and the latter is sent to the furans conversion reactor. There, crystallized fructose is solubilized with a 95 wt.% methanol aqueous solution and sulfuric acid. The reaction is conducted at 50 bars and 200ºC. Fructose is dehydrated to hydroxyl methyl furan (HMF) and, due to the excess of methanol, most HMF is converted to MMF, which is more stable than HMF.
MMF purification. The reactor effluent is then sent to a distillation system to recover the solvent and separate the MMF from other impurities. Methanol and water are recovered and returned to the furans conversion area, while methyl levulinate is recovered as a byproduct. Also, a heavies stream is recovered to be used as boiler fuel, and finally, purified MMF is recovered and directed to the FDCA production area.
FDCA production. Purified MMF is mixed with acetic acid solvent and catalyst in the oxidation reactor to be converted to FDCA. This stream is filtered to recover crude FDCA. The acetic-acid-rich liquid is purified using two distillation columns. Catalyst is also recovered, but it must be reactivated before being recycled to the process. Crude FDCA is mixed with water and hydrogen in a hydrogenation reactor, where impurities are removed. The effluent from the reactor is crystallized, and purified FDCA is recovered from the solid materials. The liquid effluent is a waste stream.
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Production Process Information
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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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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 FDCA 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 FDCA 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 FDCA 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 FDCA 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 costs associated with the construction of a plant producing FDCA from raw sugar (sucrose) in Germany. Initially, sucrose is hydrolyzed into glucose and fructose and the glucose obtained is enzymatically isomerized into fructose. It is then dehydrated in ionic liquid medium, yielding hydroxymethylfurfural, which is finally oxidized to FDCA. The process examined is based in a non-commercial route.
Details: 90 kta Germany-based plant | Q4 2024 | 107 pages | Issue B From $1,199 USD
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This analysis presents a process, in which hydroxymethylfurfural (HMF) is oxidized to generate 2,5-Furandicarboxylic Acid (FDCA). FDCA is recovered from the reaction product in solid form. The economic analysis is based on a plant located in the United States.
Details: 270 kta United States-based plant | Q4 2024 | 107 pages | Issue C From $799 USD
The cost analyses presented in this report target a 270 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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