Commodity Production Costs Report
2-Ethylhexanoic Acid Production from Butyraldehyde
2-Ethylhexanoic Acid Operating Costs & Plant Construction Costs
This report presents the economics of 2-Ethylhexanoic Acid production from Butyraldehyde in the United States. In this process, n-butyraldehyde undergoes an aldol condensation reaction yielding 2-ethylhexenal, which is then hydrogenated to form 2-ethylhexanal. The aldehyde is subsequently subjected to an oxidation reaction to produce the 2-Ethylhexanoic Acid.
The report provides a comprehensive study of 2-Ethylhexanoic Acid production and related 2-Ethylhexanoic Acid production cost, covering three key aspects: a complete description of the 2-Ethylhexanoic Acid production process examined; an in-depth analysis of the related 2-Ethylhexanoic Acid plant capital cost (Capex); and an evaluation of the respective 2-Ethylhexanoic Acid plant operating costs (Opex).
The 2-Ethylhexanoic 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 2-Ethylhexanoic 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 2-Ethylhexanoic 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.
Key reference(s): ?
The process under analysis comprises the following major sections: (1) aldol condensation; (2) hydrogenation, (3) oxidation and (4) purification.
* Aldol Condensation. The n-butyraldehyde is fed to a stirred tank along with a caustic soda solution, used as catalyst. An aldolization reaction occurs under thorough mixing, yielding butyraldol, which is immediately dehydrated to 2-ethyl-2-hexenal. The effluent from the condensation reactor is directed to a reactive distillation step, to strip off light ends and unreacted butyraldehyde from the condensation reactor effluent. The unreacted n-butyraldehyde is recycled to the reactor, while the liquid stream withdrawn from column’s bottom is fed to a caustic removal step. After the caustic removal, a stream composed primarily of 2-ethyl-2-hexenal is then routed to the hydrogenation area, downstream.
* Hydrogenation. In this section, the 2-ethyl-2-hexenal stream is combined with hydrogen and fed to a fixed-bed reactor filled with a Palladium catalyst on carbon support, where hydrogenation reaction takes place. The 2-ethyl-2-hexenal selectively reacts with hydrogen, yielding 2-ethylhexanal.
* Oxidation. The 2-ethylhexanal stream is mixed with a potassium salt of 2-ethylhexanoic acid (used as additive to enhance the selectivity of the oxidation reaction) and fed along with compressed air, to a shell and tube reactor with forced circulation, where an oxidation reaction takes place in the liquid phase. Crude acid taken off at the bottom of the oxidation reactor is routed to the purification section downstream, while the reactor off-gas, mainly containing inert nitrogen contained in the air feed, is discharged as waste.
* Purification. The purification is composed of two distillation columns operating under vacuum. The first column, the heavies column, separates a mixture of 2-Ethylhexanoic Acid and potassium salt of 2-ethylhexanoic acid by column’s bottom, which is then recycled to the oxidation reactor after a small purge to avoid the buildup of heavy impurities. The second column, the lights column, removes the light impurities from the 2-Ethylhexanoic Acid product.
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the 2-Ethylhexanoic 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 2-Ethylhexanoic 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 2-Ethylhexanoic 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 2-Ethylhexanoic 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
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