Toluene Diisocyanate from Toluene (Gas-Phase Phosgenation)
Toluene Diisocyanate Production Costs Report | Issue F | 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 TDI production from toluene and chlorine via a process similar to the Bayer Gas-Phase Phosgenation (GPP) technology in the United States. Initially, toluene is dinitrated to dinitrotoluene (DNT). Then, DNT is hydrogenated to toluenediamine (TDA). Finally, TDA reacts with phosgene in gas phase to produce TDI. The phosgene used is generated from chlorine in an on-site unit.
The report provides a comprehensive study of Toluene Diisocyanate production and related Toluene Diisocyanate production cost, covering three key aspects: a complete description of the Toluene Diisocyanate production process examined; an in-depth analysis of the related Toluene Diisocyanate plant capital cost (Capex); and an evaluation of the respective Toluene Diisocyanate plant operating costs (Opex).
The Toluene 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 Toluene 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 Toluene 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 Schematic
The process under analysis comprises three major sections: (1) Toluene Nitration; (2) DNT Reduction; and (3) TDA Phosgenation.
Toluene Nitration. The nitration of toluene occurs in two steps. In the first step Toluene reacts with nitric acid (HNO3), in the presence of sulfuric acid, to form three mononitrotoluene isomers ortho-, meta- and para-mononitrotoluenes. In the second step, nitric acid reacts with mononitrotoluene isomers in the presence of sulfuric acid to form dinitrotoluene (DNT). The acid concentration is controlled to prevent the formation of trinitrotoluenes. A mix of isomers result from the second step nitration, but the mixture called 80/20 DNT essentially contains about 80 wt% of 2,4-DNT and about 20 wt% of 2,6-DNT. The effluent is sent to a caustic wash to neutralize remaining acids.
DNT Reduction. In the reduction stage, DNT is hydrogenated in the presence of hydrogen and a Raney Nickel catalyst. Methanol is used as a solvent to keep the catalyst in suspension in the reaction medium. No isomerization takes places, so the DNT isomers are converted to their corresponding diamines. After a few purification steps 80/20 TDA is directed to next section while catalysts and reagents are recycled.
TDA Phosgenation. The final stage, the phosgenation of TDA, also takes place in two steps. First, TDA reacts with a molecule of phosgene to yield toluene dicarbamyl dichloride (TDD). Then, toluene dicarbamyl dichloride is decomposed into toluene diisocyanate and hydrochloric acid. Isomerization in this stage is also negligible. After a few purification steps 80/20 TDI is recovered as the final product and hydrogen chloride is absorbed into water to be sold as a 32 wt% HCl solution.
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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 Toluene 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 Toluene 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 Toluene 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 Toluene 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 Toluene Diisocyanate Production Cost Reports
Toluene Diisocyanate Production from DNT and Phosgene
This study reviews the costs associated with Toluene Diisocyanate (TDI) production from dinitrotoluene (DNT) and phosgene in the United States. Initially, DNT is hydrogenated to toluenediamine (TDA). Then, TDA reacts with phosgene in liquid phase to produce TDI.
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Toluene Diisocyanate Production from DNT, CO and Methanol
This report presents the economics of Toluene Diisocyanate (TDI) production from dinitrotoluene (DNT) in the United States. The process examined is a typical reductive carbonylation. DNT initially is reacted with carbon monoxide and methanol to form toluene dimethylcarbamate, which is then thermally decomposed to produce TDI.
Details: 180 kta United States-based plant | Q2 2024 | 107 pages | Issue B From $1,199 USD
The cost analyses presented in this report target a 180 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.
Toluene Diisocyanate from DNT and Cl2 (Liquid-Phase Phosgenation)
This study presents the costs associated with Toluene Diisocyanate (TDI) production from dinitrotoluene (DNT) and chlorine in the United States. Initially, DNT is hydrogenated to toluenediamine (TDA), which is reacted with phosgene in liquid phase to produce TDI. The phosgene used in this process is generated from chlorine and carbon monoxide in an on-site unit.
Details: 180 kta United States-based plant | Q2 2024 | 107 pages | Issue C From $1,199 USD
The cost analyses presented in this report target a 180 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.
Toluene Diisocyanate from Toluene (Liquid-Phase Phosgenation)
This report presents the economics of a typical liquid-phase phosgenation process for Toluene Diisocyanate (TDI) production from toluene and chlorine in the USA. Initially, toluene is submitted to a dinitration to produce dinitrotoluene (DNT), which is then hydrogenated to toluenediamine (TDA). This TDA is reacted with phosgene in liquid phase to yield TDI product. The phosgene used is generated from chlorine in an on-site unit.
Details: 220 kta United States-based plant | Q2 2024 | 107 pages | Issue D From $1,499 USD
The cost analyses presented in this report target a 220 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.
Toluene Diisocyanate from DNT and Cl2 (Gas-Phase Phosgenation)
This report shows a techno-economic analysis about Toluene Diisocyanate (TDI) production from dinitrotoluene (DNT) and chlorine in the United States. The process examined in this report is similar to the Bayer gas-phase phosgenation (GPP) technology. DNT is hydrogenated to toluenediamine (TDA), which then reacts with phosgene in gas phase to produce TDI. The phosgene used in generated from chlorine.
Details: 180 kta United States-based plant | Q2 2024 | 107 pages | Issue E From $1,199 USD
The cost analyses presented in this report target a 180 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.
Toluene Diisocyanate from Toluene (Gas-Phase Phosgenation)
This report presents the economics of TDI production from toluene and chlorine via a process similar to the Bayer Gas-Phase Phosgenation (GPP) technology in the United States. Initially, toluene is dinitrated to dinitrotoluene (DNT). Then, DNT is hydrogenated to toluenediamine (TDA). Finally, TDA reacts with phosgene in gas phase to produce TDI. The phosgene used is generated from chlorine in an on-site unit.
Details: 300 kta United States-based plant | Q2 2024 | 107 pages | Issue F 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.
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This report presents the economics of Toluene Diisocyanate (TDI) production from toluene in the United States. The process examined is a typical reductive carbonylation. Initially, dinitrotoluene (DNT) is produced via toluene dinitration, which is then reacted with carbon monoxide and methanol to form toluene dimethylcarbamate. This intermediate is thermally decomposed to produce TDI.
Details: 220 kta United States-based plant | Q2 2024 | 107 pages | Issue G From $1,199 USD
The cost analyses presented in this report target a 220 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.
Toluene Diisocyanate from Toluene (Oxidative Carbonylation)
This feasibility study presents the costs associated with TDI production from toluene in the United States. The process examined is similar to Enichem's oxidative carbonylation process. In this process, DNT is hydrogenated to toluenediamine (TDA). Then, TDA reacts with dimethyl carbonate (DMC) to produce a urethane intermediate that is finally cracked to produce TDI.
Details: 180 kta United States-based plant | Q2 2024 | 107 pages | Issue H From $1,499 USD
The cost analyses presented in this report target a 180 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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