Purified Terephthalic Acid from p-Xylene (Conventional Process)
Terephthalic Acid Production Costs Report | Issue B | Q2 2024
Report Details |
700 kta United States-based plant | Q2 2024 | 107 pages | Delivered in PDF |
This report presents a cost analysis of a 700 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 economics of Purified Terephthalic Acid (PTA) production using p-xylene as the process feedstock. The study approaches the construction of a plant in the United States employing a conventional catalytic oxidation process. In this process, p-xylene is oxidized to terephthalic acid (TPA). The TPA is subjected to separation and drying steps, and then sent to hydrogenation to obtain PTA as the final product.
The report provides a comprehensive study of Terephthalic Acid production and related Terephthalic Acid production cost, covering three key aspects: a complete description of the Terephthalic Acid production process examined; an in-depth analysis of the related Terephthalic Acid plant capital cost (Capex); and an evaluation of the respective Terephthalic Acid plant operating costs (Opex).
The Terephthalic Acid 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 Terephthalic Acid 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 Terephthalic Acid 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) Oxidation; (2) Crude terephthalic acid recovery; and (3) Purification.
Oxidation. p-Xylene is mixed with acetic acid solvent and a catalyst solution and then fed to the oxidation reactor. In the reactor, p-xylene is oxidized to terephthalic acid and most of the product generated is precipitated. Unreacted p-xylene, acetic acid, and water formed are partially vaporized and sent to a scrubber column downstream to recover the acetic acid and p-xylene. The residual gas from the scrubber is sent to a combustion unit, where volatile organic compounds are oxidized before disposal.
Crude terephthalic acid recovery. The crude terephthalic acid (CTA) slurry from the reactor passes through a crystallization step, then it is centrifuged and dried. Solvent streams recovered from CTA crystallization, CTA drying, and scrubber and part of mother liquor from centrifugation are fed to a solvent recovery step for water removal before it is recycled to the oxidation reactor. The dry CTA obtained is subjected to further purification steps since it still contains impurities that make it a product not acceptable in the polyester industry.
Purification. The CTA is dissolved in hot water and then sent to a hydrogenation step. During the hydrogenation, the undesired impurities are converted into soluble compounds, which remain dissolved in the mother liquor in a solid-liquid separation step downstream. The effluent from hydrogenation passes through a second crystallization step and is subsequently centrifuged for the separation of PTA crystals from the mother liquor. Part of the mother liquor is then recycled back to the oxidation reaction, in such a way that the dissolved hydrogenated compounds are converted to terephthalic acid. Finally, the PTA wet cake is dried and PTA as a product 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 Terephthalic Acid 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 Terephthalic Acid 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 Terephthalic Acid 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 Terephthalic Acid 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 Terephthalic Acid Production Cost Reports
Medium-Purity Terephthalic Acid Production
This report presents the economics of Medium-Purity Terephthalic Acid (MTA) production. The analysis is based on a plant located in the United States starting from p-xylene using a typical catalytic oxidation process. In this process, p-xylene is oxidized to terephthalic acid (TPA). Then, the TPA is crystallized and recovered from the liquor and MTA is obtained as the final product.
Details: 750 kta United States-based plant | Q2 2024 | 107 pages | Issue A From $799 USD
The cost analyses presented in this report target a 750 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.
Purified Terephthalic Acid from p-Xylene (Conventional Process)
This study presents the economics of Purified Terephthalic Acid (PTA) production using p-xylene as the process feedstock. The study approaches the construction of a plant in the United States employing a conventional catalytic oxidation process. In this process, p-xylene is oxidized to terephthalic acid (TPA). The TPA is subjected to separation and drying steps, and then sent to hydrogenation to obtain PTA as the final product.
Details: 700 kta United States-based plant | Q2 2024 | 107 pages | Issue B From $799 USD
The cost analyses presented in this report target a 700 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.
Purified Terephthalic Acid from p-Xylene (BP Technology)
This assessment presents the economics of Purified Terephthalic Acid (PTA) production from p-xylene. The economic analysis is based in a plant located in the United States. The process examined in this report is similar to BP X Technology. In this process, p-xylene is oxidized to terephthalic acid, which is hydrogenated to obtain PTA. Drying and storage of crude terephthalic acid is not necessary.
Details: 700 kta United States-based plant | Q2 2024 | 107 pages | Issue C From $799 USD
The cost analyses presented in this report target a 700 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.
Purified Terephthalic Acid from p-Xylene (GTC Technology)
This analysis presents production cost of Purified Terephthalic Acid (PTA) production from p-xylene. The process examined in this report is similar to that one developed by GTC Technology. Differently from the conventional technology, this process does not involve a hydrogenation step for Terephthalic Acid purification after oxidation. The economic analysis assumes a plant located in the USA..
Details: 750 kta United States-based plant | Q2 2024 | 107 pages | Issue D From $799 USD
The cost analyses presented in this report target a 750 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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