Commodity Production Costs Report
Acrylic Acid Production from Propylene
Acrylic Acid Operating Costs & Plant Construction Costs
This report presents the economics of Ester-Grade Acrylic Acid (EAA) production from chemical grade (CG) propylene in a plant located in the United States. The process consists in a two stage vapor-phase oxidation of propylene, yieding Acrylic Acid, which is then purified to obtain the Ester-Grade product.
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) Reaction and quench; (2) Product recovery; and (3) Purification.
Reaction and quench. Chemical grade (CG) propylene mixed with steam and air is fed to a two-step oxidation reaction system. Firstly, propylene is oxidized to acrolein, which is then oxidized to acrylic acid. The effluent is sent to a quench tower, where the acrylic acid formed is absorbed in water. This solution is sent to product recovery. Part of the residual gas from the top of the quench tower is recycled to the first reactor, and the remainder is incinerated.
Product recovery. The aqueous solution from quench is fed to an extractor, in which the acrylic acid is separated by means of liquid-liquid extraction with a solvent. The top of the extractor, containing the acrylic acid, is sent to a solvent separation column to recover a two-phase overheads stream. This two-phase stream is separated and the organic phase, containing the solvent, is recycled to the extractor. The aqueous phase is mixed with the raffinate from the extraction step and sent to a solvent stripper to minimize the solvent losses. The bottom stream from solvent recovery column is then fed to the light-ends cut column, where a concentrated acrylic acid stream is obtained as the bottom product. The column overhead stream, mainly comprised of acetic acid and light impurities, is sent to an incinerator.
Purification. The concentrated acrylic acid from the light-end cut column is fed to the acrylic acid column. In this column, ester-grade acrylic acid is obtained as the overhead product. The column bottoms composed of acrylic acid dimers are sent to the bottoms stripper column, where the heavy ends are separated and sent to waste, while residual acrylic acid is recycled to acrylic acid column.
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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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Details: 150 kta Germany-based plant | Q3 2024 | 107 pages | Issue D | From $799 USD
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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.
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