Production Cost Report
ICC - Is Bespoken: 0
ICC - Main References: ?
ICC - Issue: A
ICC - Volume: 366
ICC - Report ID: 366-A
ICC - Report Location: United States
ICC - Is Popular: 0
ICC - Is Developed: 1
ICC - Title: KA Oil Production
ICC - Show Overview: 1
ICC - Report Location ID: 1
ICC - Plant Capacity Unit ID: 14
ICC - Related Reports List: 019-J,047-A,047-B
ICC - Report Location Code: USA
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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/366-A.jpg
ICC - Process Overview Text: <h6>Product</h6> <p><b></b>. KA Oil (10:1) is a mixture of cyclohexanone and cyclohexanol used as an intermediate in producing caprolactam, the precursor to nylon 6. It is vital in synthesizing fibers and engineering plastics. Produced by the oxidation of cyclohexane, KA oil is stored as a liquid mixture. Its specific ratio facilitates efficient downstream processing in nylon manufacturing.</p> <h6>Raw Materials</h6> <p><b>Chemicals</b>. </p> <b>Cyclohexane</b>. Cyclohexane, a relatively stable cycloalkane, is an important intermediate in nylon manufacturing. In fact, almost all cyclohexane produced commercially is employed in the production of Adipic Acid and caprolactam, precursors to nylon. A very small fraction of the cyclohexane produced is consumed in minor miscellaneous uses, such as solvents and polymer reaction diluents. On a commercial scale, cyclohexane production is almost entirely based on hydrogenation of benzene.</p>
ICC - Process Schematic Image: //cdn.intratec.us/images/icc/process-schematics/366-A.jpg
ICC - Process Schematic Text: <p>The process under analysis comprises two major sections: (1) Oxidation; and (2) Purification.</p><p>Oxidation. Initially, cyclohexane is fed to the first of several staged air oxidation vessels, along with meta-boric acid. The cyclohexane is oxidized in the liquid-phase to cyclohexyl hydroperoxide (CHHP). In the presence of boric acid, the cyclohexyl hydroperoxide is trapped as cyclohexyl perborate ester, which in turn reacts with cyclohexane yielding borate ester and cyclohexanol. The borate ester formed is relatively stable, in such a way that the generation of undesired by-products is minimized. Next, the ester is hydrolyzed, yielding cyclohexanol and boric acid, in organic and aqueous phases, respectively. Subsequently, CHHP still present in the oxidation product is decomposed by another oxidation reaction over a fixed bed of cobalt catalysts, yielding a cyclohexanol-cyclohexanone mixture (KA oil). The boric acid present in the aqueous phase is crystallized, dehydrated, and recycled to the first oxidation reactor.</p><p>Purification. The organic effluent from CHHP oxidation goes through a series of purification steps. First, unreacted cyclohexane is stripped and recovered. Second, heavy ends are removed via distillation to be used as fuel, yielding the refined KA Oil product.</p>
ICC - Short Description: This report presents the economics of Ketone-Alcohol (KA) Oil production from cyclohexane in the United States. In this pricess, cyclohexane is initially oxidized with air to produce a mixture of cyclohexanol and cyclohexanone, also known as KA Oil.
ICC - Main Product: KA Oil
ICC - Plant Capacity: 300.00
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KA Oil Production

KA Oil Production Costs Report | Issue A | Q2 2024

Production Cost Report

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300 kta United States-based plant   |   Q2 2024   |   107 pages   |   Delivered in PDF

This report presents a cost analysis of a 300 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

Process Consumptions

Labor Requirements

Plant Capital Cost Summary

Operating Cost Summary

Production Costs Datasheet

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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

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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

Costs in Different Countries Add-on

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Content Highlights

Plant Capital Cost Summary

Summary outlining the capital cost required for building the KA Oil 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 KA Oil 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 KA Oil 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 KA Oil 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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Other Related Production Cost Reports

Adipic Acid Production from KA Oil

This report presents the economics of Adipic Acid production from a mixture of cyclohexanone and cyclohexanol (known as KA oil) in the United States. The process portrayed comprises the oxidation of the KA oil with nitric acid to produce Adipic Acid. A mixture of adipic, glutaric, and succinic acids is generated as by-product.

Details: 350 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue J   From $799 USD

The cost analyses presented in this report target a 350 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.

Cyclohexane from Benzene and Hydrogen (Liquid-Phase Process)

This feasibility study shows the economics of Cyclohexane production from benzene using a liquid phase hydrogenation process in the presence of a nickel-based catalyst. The economic analysis presented is based on a plant constructed in the United States.

Details: 200 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue A   From $799 USD

The cost analyses presented in this report target a 200 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.

Cyclohexane from Benzene and Hydrogen (Vapor-Phase Process)

This feasibility study shows the economics of Cyclohexane production from benzene using a vapor phase hydrogenation process in the presence of a nickel-based catalyst. The economic analysis presented is based on a plant constructed in the United States.

Details: 200 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue B   From $999 USD

The cost analyses presented in this report target a 200 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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