Commodity Production Costs Report

Bio-Acrylic Acid Production from Raw Sugar (Single-Step Process)

Acrylic Acid Operating Costs & Plant Construction Costs

150 kta United States-based plant | 107 Pages | Issue D | 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 Germany. The process is based on the fermentation route of raw sugar, 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 two major sections: (1) Fermentation; and (2) Extraction and Distillation.

Fermentation. The culture media used in the fermentation is prepared by diluting the raw sugar and nutrients in water. Such media is sterilized by direct steam injection, cooled and sent to fermentor. It is assumed that the fermentation is carried out in continuous mode with cell recycling, and under anaerobic process conditions in an agitated, jacketed fermentor. The pH control of the fermentation is made by addition of recycled sodium carbonate, in such a way that the pH of the fermentation broth is maintained at around 7. The temperature is controlled between 35 and 40 °C via circulation of cooling water in the fermentor jacket. The fermentation yield considered is about 70% and the acrylate concentration is about 50 g/l. After fermentation, biomass is separated from the broth and partially recycled to the fermentation.

Extraction and Distillation. The sodium acrylate solution exiting from the Cells Separation is pumped into a multi-stage countercurrent extraction unit. There, extractant separates the Acrylic Acid in the organic phase. The aqueous phase containing sodium bicarbonate is decomposed at high temperatures, producing dissolved sodium carbonate, that is recycled as neutralization component in the fermentation. The organic phase is initially decompressed in a flash unit, where the majority of the dissolved carbon dioxide is released. The liquid stream from the flash vessel is then fed to a distillation column, where under reduced pressure and elevated temperature conditions the water remained in the organic phase is removed. The acid is separated from extractant in a distillation column, and Glacial Acrylic Acid is obtained as distillate. The extractant is then back-extracted with water in a multi-stage extractor train and recycled.

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  • Production Process Information
  • Process Consumptions
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  • Plant Capital Cost Summary
  • Operating Cost Summary
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 80 Pages | 22 Tables | 9 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
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  • 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
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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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