Commodity Production Costs Report
Acrylic Acid Production from Natural Gas
Acrylic Acid Operating Costs & Plant Construction Costs
This report presents the economics of Ester-Grade Acrylic Acid (EAA) production from natural gas in the United States. Initially, methane in the natural gas feed is cracked to acetylene which is reacted carbon monoxide generated by feed combustion, yielding 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): ?
The process under analysis comprises three major sections: (1) Acetylene Production; (2) Carbon Monoxide Separation; (3) Acrylic Acid Production; and (4) Methanol Production.
Acetylene Production. Natural gas feed and oxygen are preheated and fed to a burner. Part of the methane is burned, while the remainder is cracked to acetylene. The hot gas leaves the reaction chamber, and it is cooled down as it passes through sprays of water. Soot present in the cracked gas is partly removed from the gas by the water quench, with the remainder being removed by a recirculated water wash in a cooling column and an electrofilter. The gaseous outlet is compressed and recovered by selective absorption into N-methylpyrrolidinone (NMP) solvent in the main scrubber. This column off-gas is a crude synthesis gas stream. The acetylene solution is subsequently passed through a stripper, where purified acetylene is obtained as a side stream.
Carbon Monoxide Separation. The crude synthesis gas is partially treated to remove carbon dioxide and hydrogen from carbon monoxide (CO). The purified CO is then sent to the Acrylic Acid Production section.
Acrylic Acid Production. Acetylene is absorbed in THF and fed to a multi-tube reactor, where it is reacted with CO, yielding Acrylic Acid in the presence of a mixture of nickel bromide with a cupric bromide as catalyst. The product stream is passed through purification steps, where the acrylic acid is degassed, extracted and distilled to remove THF, acetic acid, water and dimers.
Methanol Production. The remaining part of crude syngas from acetylene scrubber is mixed with hydrogen from CO separation, compressed and directed to the methanol converter. Methanol is produced from reactions of carbon monoxide and carbon dioxide with hydrogen in the presence of a copper-based catalyst. The effluent is sent to a gas/liquid separator, then liquid stream is directed to two distillation columns, in which light ends and heavy impurities are recovered and methanol is obtained.
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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 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 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.
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