Laurolactam from Cyclododecane (Oximation with Hydroxylamine)
Laurolactam Production Costs Report | Issue A | Q2 2024
Report Details |
20 kta United States-based plant | Q2 2024 | 107 pages | Delivered in PDF |
This report presents a cost analysis of a 20 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 Laurolactam production from cyclododecane in the United States. Initially, cyclododecane is oxidized to cyclododecanol. Subsequently, the cyclododecanol obtained is dehydrogenated to cyclododecanone. Then, the cyclododecanone is submitted to an oximation reaction with hydroxylamine. Finally, the cyclododecanone oxime produced is converted to laurolactam by Beckmann rearrangement.
The report provides a comprehensive study of Laurolactam production and related Laurolactam production cost, covering three key aspects: a complete description of the Laurolactam production process examined; an in-depth analysis of the related Laurolactam plant capital cost (Capex); and an evaluation of the respective Laurolactam plant operating costs (Opex).
The Laurolactam 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 Laurolactam 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 Laurolactam 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 four major sections: (1) Cyclododecane Oxidation; (2) Cyclododecanol Dehydrogenation; (3) Cyclododecanone Oximation; and (4) Oxime Rearrangement.
Cyclododecane Oxidation. Initially, fresh boric acid, recovered boric acid and fresh cyclododecane are mixed and fed to jacketed and agitated reactors. Cyclododecane is oxidized by air in the presence of a boric acid catalyst, yielding cyclododecanol. The oxidation is carried out in atmospheric pressure, at temperatures from 140 to 160°C. As the boric acid esterifies part of the cyclododecanol product, the effluent is sent to a mixer, where the boric esters are hydrolyzed. The mixture settles and the aqueous phase, containing boric acid, is removed. The oil phase is washed with caustic soda and directed to a settler for water removal. The mixture is passed through a water scrubber and is fed to a column where the unconverted cyclododecane is distilled from the oil phase under reduced pressure. In a second distillation heavy compounds and residues are removed from cyclododecanol.
Cyclododecanol Dehydrogenation. The cyclododecanol obtained is then dehydrogenated to cyclododecanone over a catalyst consisting of copper on alumina. The effluent is fed to a flash vessel for hydrogen release and is twice distilled, so light and heavy ends are removed.
Cyclododecanone Oximation. The purified cyclododecanone is then reacted with hydroxylamine sulfate in oximation reactors, where the cyclic ketone is converted to cyclododecanone oxime by condensation. This reaction takes place in hydrocumene, used as solvent, under agitation. Ammonia is added to the reactors for pH control. The mixture is fed to a settler, and the oil phase is sent to next step, where oxime is extracted with sulfuric acid from hydrocumene.
Oxime Rearrangement. The solution of a cyclododecanone oxime sulfate adduct in sulfuric acid is then fed to jacketed agitated reactors. Under low pH and elevated temperatures, the cyclododecanone oxime is converted to Laurolactam via a Beckmann rearrangement. The reaction product is washed and neutralized by caustic soda in the presence of hydrocumene, in order to favor the subsequent settling. The purpose is to remove both residual catalyst, salts and acid entrained in the organic phase. After three distillation columns, which separate lights, hydrocumene and heavies, Laurolactam is obtained.
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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 Laurolactam 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 Laurolactam 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 Laurolactam 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 Laurolactam 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 Laurolactam production from cyclododecanone. The process examined involves the oximation of cyclododecanone raw material and the subsequent rearrengement of the cyclododecanone oxime formed to yield Laurolactam. The economic analysis performed assumes a plant located in the United States.
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