Polyethylene Furanoate Production from FDCA
Polyethylene Furanoate Production Costs Report | Issue A | Q2 2024
Report Details |
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.
Report Abstract
This report presents the economics of Polyethylene Furanoate (PEF) production from monoethylene glycol (MEG) and 2,5-furandicarboxylic acid (FDCA). In the process under analysis, FDCA and MEG are polymerized to PEF in two polymerization steps: melt-phase polymerization and solid-state polymerization. The economic analysis provided assumes a plant located in the United States.
The report provides a comprehensive study of Polyethylene Furanoate production and related Polyethylene Furanoate production cost, covering three key aspects: a complete description of the Polyethylene Furanoate production process examined; an in-depth analysis of the related Polyethylene Furanoate plant capital cost (Capex); and an evaluation of the respective Polyethylene Furanoate plant operating costs (Opex).
The Polyethylene Furanoate 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 Polyethylene Furanoate 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 Polyethylene Furanoate 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 two major sections: (1) Melt-phase polymerization; and (2) Solid-state polymerization.
Melt-phase polymerization. MEG and FDCA are initially fed to the paste system which prepares, in batches, a uniform feed slurry for melt-polymerization downstream. The mixture then passes through two agitated and jacketed reactors, in which esterification takes place generating bis(2-hydroxyethyl)-2,5-furandicarboxylate (BHEF). The BHEF monomer is fed to an agitated, jacketed reactor. Here, vacuum and heat are applied for the removal of water and ethylene glycol, shifting the reaction equilibrium towards polymerization. Antimony glycolate is used as catalyst. This pre-polymerization generates PEF oligomers. In the polycondensation step, the PEF oligomers condensate, increasing the degree of polymerization. The reaction occurs at a rotating disc reactor under an even higher vacuum, removing water and excess MEG. Here, higher molecular weight PEF chains are generated, yielding a textile fiber-grade PEF. Gaseous effluents from all reactors are condensed and fed to a distillation column where MEG is recovered in the bottom and recirculated. The previous melt-phase polymerization is concluded by a Pelletizing step, in which the molten PEF is extruded, cooled, and chopped into cylindrical shapes. The amorphous PEF chips are screened, classified, dried and then conveyed to a silo.
Solid-state polymerization. The PEF chips are crystallized, to not stick together or agglomerate due to high polymerization temperatures downstream. The crystallized particles are then polycondensed in the SSP reactor, a long cylindrical hopper-type vessel. The bottle-grade PEF chips are fed to a fluidized-bed cooler, which cools down the PEF and removes dust. The PEF chips are homogenized and packed in bags.
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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 Polyethylene Furanoate 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 Polyethylene Furanoate 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 Polyethylene Furanoate 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 Polyethylene Furanoate 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 Polyethylene Furanoate Production Cost Reports
Polyethylene Furanoate Production from Glucose
This report, in turn, presents the economics of Polyethylene Furanoate (PEF) production from monoethylene glycol (MEG) and glucose syrup in the United States. In this process, a glucose is isomerized to fructose. Then, fructose is converted to methoxy methyl furan (MMF) intermediate, which is oxidized to FDCA. This process is similar to Avantium YXY. FDCA generated and MEG are then polymerized to PEF in melt-phase and solid-state polymerization.
Details: 300 kta United States-based plant | Q2 2024 | 107 pages | Issue B From $1,499 USD
The cost analyses presented in this report target a 300 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.
Polyethylene Furanoate Production from Raw Sugar
This report presents the economics of Polyethylene Furanoate (PEF) production from raw sugar and monoethylene glycol (MEG) similar to Avantium YXY in Germany. Initially, raw sugar is inverted to fructose and glucose, which is isomerized to fructose. Then, fructose is converted to methoxy methyl furan (MMF), which is oxidized to FDCA. FDCA generated and MEG are then polymerized to PEF in melt-phase and solid-state polymerization.
Details: 300 kta Germany-based plant | Q2 2024 | 107 pages | Issue C From $1,499 USD
The cost analyses presented in this report target a 300 kta (kilo metric ton per annum per annum) Germany-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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FDCA Production from Glucose
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.
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