Nylon 6, 6 Production from Adipic Acid & HMDA (Continuous Process)
Nylon 66 Production Costs Report | Issue B | Q2 2024
Report Details |
120 kta United States-based plant | Q2 2024 | 107 pages |
This report presents a cost analysis of a 120 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 Nylon 6,6 production from adipic acid and hexamethylenediamine (HMDA) via formation of hexamethylene diamonium adipate salt in the United States. The process analyzed consists of a continuous polycondensation process.
The report provides a comprehensive study of Nylon 66 production and related Nylon 66 production cost, covering three key aspects: a complete description of the Nylon 66 production process examined; an in-depth analysis of the related Nylon 66 plant capital cost (Capex); and an evaluation of the respective Nylon 66 plant operating costs (Opex).
The Nylon 66 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 Nylon 66 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 Nylon 66 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) salt generation; (2) polymerization; and (3) finishing.
Salt generation. An adipic acid solution is formed by mixing adipic acid powder with water and molten HMDA. The solution is fed to a recirculation reactor, from which a 60 wt% nylon salt solution is withdrawn. The solution must be further treated for impurities removal before being fed to an intermediate tank.
Polymerization. The nylon salt solution from the intermediate tank is concentrated in an evaporator to about 80 wt% and fed to the first of three polymerization stages. The elevated reaction temperatures cause water and minor amounts of HMDA to evaporate and be collected by a column at the top of the reactor. HMDA is recovered and recycled to the reactor, while water is purged from the process. The liquid reaction mixture is than transferred to the second polymerization stage. At this point, it comprises 10 wt% water. In the second stage, further conversion is achieved by temperature increase. The polymer melt obtained is further reacted in a third stage at reduced pressures for residual moisture removal and finally transferred to the finishing section.
Finishing. The polymer melt is cut into pellets in an underwater pelletizing strand system and subsequently fed to a fluid bed dryer for moisture removal. The dry pellets are finally homogenized in mixing silos and fed to the packing system.
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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 Nylon 66 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 Nylon 66 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 Nylon 66 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 Nylon 66 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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Nylon 6, 6 Production from Adipic Acid & HMDA (Batch Process)
This report presents the economics of Nylon 6,6 production from adipic acid and hexamethylenediamine (HMDA) via formation of hexamethylene diamonium adipate salt in the United States. The process analyzed consists of a typical batch polycondensation process.
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