Commodity Production Costs Report

Acrylic Acid Production from Glycerol

Acrylic Acid Operating Costs & Plant Construction Costs

100 kta United States-based plant | 107 Pages | Issue B | Q3 2024
Starting at $799 USD | See Report Editions Prices

It presents the economics of Ester-Grade Acrylic Acid (EAA) production from crude glycerol in the USA using a two-step process similar to Arkema technology. In the process examined, crude glycerol, obtained from biodiesel plants, is dehydrated to acrolein, which is subsequently oxidized to Acrylic Acid.

The report provides a comprehensive study of Acrylic Acid production and related Acrylic Acid production cost, covering three key aspects: a complete description of the Acrylic Acid production process examined; an in-depth analysis of the related Acrylic Acid plant capital cost (Capex); and an evaluation of the respective Acrylic Acid plant operating costs (Opex).

The Acrylic 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 Acrylic 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 Acrylic 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): ?

Acrylic Acid Production Cost Report Process Schematic

The process under analysis comprises three major sections: (1) Crude Glycerol Treatment; (2) Reactions; and (3) Acrylic Acid Recovery.

Crude Glycerol Treatment. Initially, the crude glycerol stream is first mixed with a surfactant to precipitate soaps dissolved in the glycerol, then it is fed to an oil-water separator to remove free oils that might be contaminating the glycerol. The main stream is centrifuged and fed to an ion exchanger vessel, where dissolved salts precipitate. The glycerol is sent to a distillation column, where dissolved lighters and heavier contaminants are separated

Reactions. In the first reaction, glycerol is dehydrated to acrolein in the presence of a solid Bronsted acid catalyst, like tungsten oxide/zirconium oxide. Air is also added to the system to provide oxygen to the reaction medium. The presence of oxygen decreases coke formation in the catalyst and increases the reaction yield. Water and heavy by-products produced in the first reaction are removed in an absorption column to increase acrolein partial pressure in the second reaction, thus increasing its yield and selectivity for acrylic acid. In the second reaction, acrolein conversion takes place in the presence of molybdenum vanadium oxides catalysts.

Acrylic Acid Recovery. Since acrylic acid may spontaneously polymerize when subject to high temperatures, the columns of acrylic acid recovery section are fed with polymerization inhibitors and operated at or below atmospheric pressure to allow low bottom temperatures. The acrylic acid, absorbed in water, is quenched and purified by extraction with an organic solvent and distillation to remove the solvent. The crude acrylic acid stream is directed to another two columns, where first light ends are stripped off and acrylic dimers are removed. The last column overhead, consisting of high purity ester-grade acrylic acid, is condensed and stored.

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  • Production Process Information
  • Process Consumptions
  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
  • Production Costs Datasheet
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 80 Pages | 22 Tables | 9 Images

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Table of Contents


Features
  • Production Process Information
  • Process Consumptions
  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
  • Production Costs Datasheet
  • Plant Capital Cost Details
  • Operating Cost Details
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 90 Pages | 28 Tables | 13 Images

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Table of Contents


Features
  • 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
  • Costs in Different Countries Add-on
  • See All Features

  • 107 Pages | 34 Tables | 22 Images
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Content Highlights

Plant Capital Cost Summary

Summary outlining the capital cost required for building the Acrylic 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 Acrylic 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 Acrylic 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 Acrylic 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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This report shows a feasibility study of bio-based Acrylic Acid production from glucose syrup in a plant assumed to be located in the United States. The process is based on the fermentation route of glucose, yielding Acrylic Acid, similar to the speculative process proposed by the Delft University of Technology.

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Glacial Acrylic Acid from Crude Acrylic Acid (Crystallization)

This report presents the costs associated with the construction of an industrial plant, in the United States, for crude acrylic acid purification to produce Glacial Acrylic Acid. The purification process examined is based on crude acrylic acid crystallization.

Details: 140 kta United States-based plant | Q3 2024 | 107 pages | Issue H | From $799 USD

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Butyl Acrylate Production from Acrylic Acid and Butanol

This report approaches the production of n-Butyl Acrylate from acrylic acid and n-butanol. The process examined is similar to the Synthomer's Butyl Acrylate Process. In this process acrylic acid and n-butanol are directly converted to Butyl Acrylate via an esterification reaction catalyzed by p-Toluene Sulfonic Acid. The economic analysis performed assumes a plant located in the United States.

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