Commodity Production Costs Report
Acetaldehyde Production from Ethanol
Acetaldehyde Operating Costs & Plant Construction Costs
This report presents the economics of Acetylene production from ethanol using a catalytic oxidation process. In this process, ethanol is oxidized in the vapor phase over a silver catalyst. The economic analysis presented assumes a plant constructed in the United States.
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): ?
Products
Acetaldehyde. Acetaldehyde (also known as ethanal) is an important aldehyde, mainly used as chemical intermediate in the production of acetic acid, peracetic acid, and pyridine basis.
Acetic Acid. Acetic acid (also known as ethanoic acid, hydrogen acetate) is a carboxylic acid found in dilute solutions in plant and animal systems. This chemical is widely used in organic processes, primarily in the production of polymers derived from vinyl acetate, used in paints and coatings, cellulose used to produce acetate fibers, and as solvent. While 2–12 wt% acetic acid solutions, usually called vinegar, have long been produced by ethanol fermentation, nowadays the commercial production of acetic acid is mainly based on methanol carbonylation and liquid-phase oxidation of n-butane.
Raw Material
Ethanol. Ethanol, also known as ethyl alcohol, may work as a solvent, a germicide, a fuel, and as a chemical intermediate for other organic chemicals. Currently, ethanol is mostly produced via fermentation of sugars, which can be obtained from crops, such as sugarcane and starch. However by relying on the sugar and starch content of food crops, ethanol production competes with food production. Therefore, recent research focus on the use of low-value raw materials, often deemed “waste”, to produce ethanol. That low-value feed can be biomass of lignocellulosic material found in wood, sugarcane bagasse and grain crop stubbles, or can be carbon monoxide found in waste gas streams from a range of industries. Lignocellulosic biomass could represent a new fermentable raw material if hydrolysis of this material is performed. Technological advances in this reaction still need to be achieved in order to make it economically feasible and render this usage of the agricultural residues competitive with respect to others, such as heat generation by burn.
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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 Acetylene (Vapor-Phase Hydration)
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.
Details: 70 kta United States-based plant | Q3 2024 | 107 pages | Issue D | From $799 USD
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Other Related Production Cost Reports
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
Ethanol from Wood Chips (Gasification and Mixed Alcohols Synthesis)
This report presents the economics of Anhydrous Ethanol production from wood chips in the United States. In the process examined, wood feedstock is submitted to direct gasification, producing synthesis gas. Next, the syngas is converted to mixed alcohols. The alcohol mixture is then distilled, yielding ethanol and a mixture of higher molecular weight alcohols.
Details: 100 kta United States-based plant | Q3 2024 | 107 pages | Issue S | From $799 USD
Cellulosic Ethanol from Corn Stover (Ammonia Conditioning)
This study presents the economics of second generation Ethanol production from corn stover in the United States. The process under analysis consists in a biochemical conversion composed of three main steps. Initially, biomass undergoes pretreatment with dilute acid and ammonia conditioning. Then, the cellulose is hydrolyzed to sugars, which are fermented to ethanol.
Details: 200 kta United States-based plant | Q3 2024 | 107 pages | Issue A | From $799 USD
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