Commodity Production Costs Report
Acrolein Production
Acrolein Operating Costs & Plant Construction Costs
This report presents the economics of Acrolein production from propylene in the United States, via catalytic oxidation.
The report provides a comprehensive study of Acrolein production and related Acrolein production cost, covering three key aspects: a complete description of the Acrolein production process examined; an in-depth analysis of the related Acrolein plant capital cost (Capex); and an evaluation of the respective Acrolein plant operating costs (Opex).
The Acrolein 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 Acrolein 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 Acrolein 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 can be divided into two main areas: (1) Acrolein generation; (2) Crude Acrolein recoveryand (3) Acrolein refining.
Acrolein generation. Propene is mixed with air and inert gas and is fed to a multitubular fixed-bed reactor, yielding Acrolein and water. The reactor is cooled by a recirculating molten salt bath. The salt, in turn, is used to generate steam. Air is supplied by air compressors, while the inert gas comprises gases recovered from process downstream operations.
Crude Acrolein recovery. Acrolein gas is scrubbed with water in a quench tower to remove mainly acrylic acid by condensation. Water generated in the reaction also condenses during this step. The quench tower offgas is then absorbed in cold water, forming an Acrolein-rich aqueous solution. Acrolein is stripped from the solution in the desorption column.
Acrolein refining. Acrolein-rich gas from the desorption column is condensed and fed to a light ends column for removing impurities such as acetaldehyde and further purified in the heavy ends column for recovering refined Acrolein (95.5 wt%).
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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 Acrolein 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 Acrolein 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 Acrolein 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 Acrolein 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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