Commodity Production Costs Report
Acetaldehyde Production from Acetylene (Vapor-Phase Hydration)
Acetaldehyde Operating Costs & Plant Construction Costs
This report approaches the economics of an acetylene hydration process in the United States. In this study, hydration is carried out in vapor phase with steam over a solid catalyst.
The report provides a comprehensive study of Acetaldehyde production and related Acetaldehyde production cost, covering three key aspects: a complete description of the Acetaldehyde production process examined; an in-depth analysis of the related Acetaldehyde plant capital cost (Capex); and an evaluation of the respective Acetaldehyde plant operating costs (Opex).
The Acetaldehyde 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 Acetaldehyde 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 Acetaldehyde 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 two major sections: (1) Hydration; and (2) Purification.
Hydration. Acetylene and excess steam are heated to reaction temperature and fed to vertical reactor tubes operating alternatively, where the feed contacts catalyst at 350-400 °C. The reactors are arranged in such a way that while three reactors are actually operating, one is in catalyst regeneration cycle. The reaction medium is passed successively through three reactors, with fresh feed mixture and steam being fed to each of them; while the reaction is highly exothermic, quench water is employed for cooling each reactor effluent back to the desired reaction temperature. At the end, about 65% of the acetylene in the mixture react, with 90-95% of the reacted acetylene being converted to acetaldehyde.
Purification. The gaseous stream from the reactors, comprising ethylene, some unreacted acetylene, acetaldehyde product, and steam, is cooled and fed to a flash vessel, where heavy reaction by-products are removed and discarded, most of the water is recovered and recycled for quenching reactors effluents. The crude Acetaldehyde stream is further purified by distillation; the unreacted acetylene and remaining water are recycled.
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Professional report based on Q3 2024 economic data, ensuring timely evaluations.
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Acetaldehyde 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 Acetaldehyde 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 Acetaldehyde 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 Acetaldehyde 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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Other Acetaldehyde Production Cost Reports
Acetaldehyde Production from Ethylene (Two-Step Process)
This report presents a techno-economic analysis of Acetaldehyde production from ethylene in the United States using a typical two-step oxidation process. In this process ethylene is oxidized by air to Acetaldehyde in tubular reactors, using a palladium/copper catalyst system.
Details: 70 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $999 USD
Acetaldehyde Production from Acetylene (Liquid-Phase Hydration)
This study concerns Acetaldehyde production in the United States. The process reviewed in the study is an acetylene hydration in liquid phase similar to the technology developed by Chisso.
Details: 70 kta United States-based plant | Q3 2024 | 107 pages | Issue C | From $999 USD
Acetaldehyde Production from Ethylene (Single-Step Process)
This report assesses the economics of Acetaldehyde production from ethylene in the United States using a typical single-step oxidation process. In this process, ethylene oxidation is carried out by using high purity oxygen.
Details: 70 kta United States-based plant | Q3 2024 | 107 pages | Issue E | From $999 USD
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Other Related Production Cost Reports
Acetylene Production from Calcium Carbide
This study presents the economics of Acetylene production from calcium carbide in the United States via wet process. In the process, calcium carbide reacts with water to form Acetylene. Hydrated lime is generated as by-product.
Details: 200 kta United States-based plant | Q3 2024 | 107 pages | Issue D | From $799 USD
Ethyl Acetate Production from Acetaldehyde
This report examines the economics of Ethyl Acetate production from acetaldehyde in the United States via Tishchenko reaction, which refers to the dimerization of acetaldehyde in the presence of an alkoxide catalyst to form the ester.
Details: 100 kta United States-based plant | Q3 2024 | 107 pages | Issue D | From $799 USD
Acetylene Production from Natural Gas (Partial Combustion Process)
This report presents the economics of Acetylene production from natural gas using a partial combustion process similar to that developed by BASF. In this process, methane from natural gas is cracked in high temperatures to acetylene and hydrogen. The economic analysis developed is based on a plant constructed in the United States.
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