MDI Production from Aniline (Phosgenation Process)
Methylene Diphenyl Diisocyanate Production Costs Report | Issue A | Q4 2024
| Report Details |
| 50 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 50 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 study presents the costs associated with the construction of a plant producing MDI from aniline and formaldehyde in the USA. In this study aniline reacts with formaldehyde to form a mixture of diphenyl methane diamine and polymeric amines. Then, this mixture reacts with phosgene to produce MDI and polymeric MDI. The phosgene used is generated from chlorine in an on-site unit.
The report provides a comprehensive study of Methylene Diphenyl Diisocyanate production and related Methylene Diphenyl Diisocyanate production cost, covering three key aspects: a complete description of the Methylene Diphenyl Diisocyanate production process examined; an in-depth analysis of the related Methylene Diphenyl Diisocyanate plant capital cost (Capex); and an evaluation of the respective Methylene Diphenyl Diisocyanate plant operating costs (Opex).
The Methylene Diphenyl Diisocyanate 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 Methylene Diphenyl Diisocyanate 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 Methylene Diphenyl Diisocyanate 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 Overview
Product
MDI. MDI or Methylene Diphenyl Diisocyanate is a chemical primarily used in the production of polyurethane foams, elastomers, and coatings. It reacts with polyols to form flexible and rigid foams, essential in insulation and cushioning applications. MDI is produced via the phosgenation of methylene dianiline and is stored as a liquid. It is crucial for producing high-performance materials like adhesives and sealants, and its versatility enables its use in automotive, construction, and furniture industries.
Raw Materials
Formalin. Formaldehyde is a colorless, strong-smelling gas remarkably versatile as a chemical intermediate - it is widely used for the production of resins and coatings employed in the manufacture of building materials and household products. Since the pure gas slowly polymerizes at temperatures lower than 80°C, formaldehyde is usually available as a liquid solution in water with small amounts of methanol. This solution is called formalin. Most of world's formalin is commercially manufactured from methanol and air in the presence of a silver (or a metal oxide) catalyst.
Chlorine. Chlorine figures among the most important chemical commodities. It is an indispensable intermediate in the chemical industry, employed in the manufacture of a multitude of end products (e.g. materials of construction, solvents, pesticides, etc). Most of chlorine produced on commercial scale is based on electrolysis of aqueous sodium chloride (brine), which also generates caustic soda and hydrogen as co-products (chlor-alkali processes).
Aniline. Aniline is an important organic compound used primarily in the production of polyurethane foam, rubber processing chemicals, and dyes. Its versatility in chemical synthesis makes it a key intermediate for several industrial applications. Aniline is produced by the hydrogenation of nitrobenzene. It is stored as a liquid at room temperature and requires careful handling due to its toxicity.
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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 Methylene Diphenyl Diisocyanate 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 Methylene Diphenyl Diisocyanate 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 Methylene Diphenyl Diisocyanate 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 Methylene Diphenyl Diisocyanate 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
Other Methylene Diphenyl Diisocyanate Production Cost Reports
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This report presents the economics of Methylene Diphenyl Diisocyanate (MDI) production from aniline and formaldehyde using a typical oxidative carbonylation process located in the USA. In this process, aniline undergoes oxidative carbonylation to give ethyl phenylcarbamate (EPC). Then, the EPC reacts with formaldehyde to form diphenylene diurethane (MDU). Finally, MDU is thermally decomposed to MDI.
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The cost analyses presented in this report target a 50 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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