Commodity Production Costs Report

Bio-Acrylic Acid Production from Glucose (Single-Step Process)

Acrylic Acid Operating Costs & Plant Construction Costs

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

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.

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) Fermentation; (2) Product Treatment and Purification; and (3) Components Recovery.

Fermentation. Fermentation media is prepared by mixing glucose, corn steep liquor and water recovered downstream, and fed to agitated fermentors. The pH control is made by addition of make-up and recycled sodium carbonate. The fermentation broth is centrifugated to separate cells and other suspended solids. The supernatant of the centrifugation, containing sodium acrylate, is sent to Liquid-Liquid Extraction, while the retentate is partially recycled to the fermentors, with the remainder being disposed.

Product Treatment and Purification. The sodium acrylate solution from Cells Separation is sent to L-L Extraction, where it is contacted in countercurrent flow with an extractant solvent. An aqueous phase containing sodium bicarbonate and residual sodium acrylate is directed to Sodium Carbonate (Na2CO3) tegeneration. An organic phase containing the extractant and acrylic acid is passed through a flash unit to remove most of the dissolved carbon dioxide (CO2), and then routed to Water Removal Column. In this column, water is removed, and a bottom product is sent to the Acrylic Acid Column. Glacial acrylic acid (99.7 wt.% purity) is obtained as the column overhead, while the extractant solvent is recovered from the bottom and routed to back extraction.

Components Recovery. In back extraction, the solvent is contacted in countercurrent with hot water, obtaining two phases: an aqueous phase containing impurities and unconverted glucose, disposed as wastewater, and an organic phase containing the solvent, sent to CO2 Compression and Absorption. Part of the carbon dioxide streams released throughout the process is also fed to this area. The solution formed is used as the extractant in the liquid-liquid extraction. The sodium bicarbonate solution from L-L Extraction is decomposed at high temperatures in the Na2CO3 Regeneration, producing carbon dioxide and dissolved sodium carbonate. The solution is passed through a sequence of evaporation steps for partial water removal and recycled as a neutralization component in the fermentation process.

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 80 Pages | 22 Tables | 9 Images

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Table of Contents


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  • Production Process Information
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  • Operating Cost Summary
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 90 Pages | 28 Tables | 13 Images

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Table of Contents


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  • 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
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  • 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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