Vinyl Acetate Production from Acetic Acid and Ethylene
Vinyl Acetate Production Costs Report | Issue A | Q2 2024
Report Details |
350 kta United States-based plant | Q2 2024 | 107 pages | Delivered in PDF |
This report presents a cost analysis of a 350 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 Vinyl Acetate production from acetic acid and ethylene in the United States, via a typical vapor-phase oxidation process. In this process, vapor acetic acid, ethylene and oxygen react in a catalytic multi-tube reactor, producing Vinyl Acetate, which is further purified.
The report provides a comprehensive study of Vinyl Acetate production and related Vinyl Acetate production cost, covering three key aspects: a complete description of the Vinyl Acetate production process examined; an in-depth analysis of the related Vinyl Acetate plant capital cost (Capex); and an evaluation of the respective Vinyl Acetate plant operating costs (Opex).
The Vinyl Acetate 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 Vinyl Acetate 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 Vinyl Acetate 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) Reaction; (2) Separation; and (3) Purification.
Reaction. Make-up and recycled acetic acid streams pass through a vaporizer, along with fresh and recycled ethylene. The resulting feed stream, containing excess ethylene over acetic acid, is mixed with oxygen, preheated, and fed to multi-tube reactors. An oxidation reaction occurs over a palladium and gold catalyst. Heat is removed by evaporative cooling on the shell of the reactors. In the end, 8-10 wt% of ethylene and 15-35 wt% of acetic acid are converted to Vinyl Acetate. Water, CO2, and small quantities of ethyl acetate, ethylidene diacetate, and glycol acetates are the main by-products.
Separation. The reactor effluent is cooled and fed to the predehydration column, where a crude VAM stream is withdrawn from the bottom and stored. The overhead stream is separated into an organic phase, recycled to the column, and an aqueous phase, directed to a decanter downstream. The uncondensed gas is washed by acetic acid and the solution formed is routed to the crude VAM tank, while the gas from the scrubber is recycled to the reaction. Part of this gas is washed with water to remove residual acetic acid and directed to the crude VAM Tank. After water washing, the gas is directed to an absorption column, for CO2 removal by a potassium carbonate solution.
Purification. In the azeotropic column, the VAM-water mixture from the crude VAM tank and the aqueous phase separated in the predehydration column are distilled and fed to a decanter. At this point, the organic phase containing VAM is separated and directed to the light-ends column. The aqueous phase is routed to the wastewater column, which separates residual VAM from wastewater. Ethyl acetate is withdrawn and discharged, and acetic acid is recycled to the caporizer. The light-ends column strips off acetaldehyde and other volatiles from the crude Vinyl Acetate. Finally, residual acetic acid and heavy ends are removed in the pure VAM column, yielding Vinyl Acetate with 99.9 wt% purity.
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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 Vinyl Acetate 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 Vinyl Acetate 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 Vinyl Acetate 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 Vinyl Acetate 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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This feasibility study examines the economics of a process producing Vinyl Acetate from acetic acid and acetylene. In the process examined, acetic acid and acetylene react in the vapor phase in the presence of a supported metal catalyst to produce vinyl acetate. The economic analysis performed is based on a plant constructed in the United States.
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