Commodity Production Costs Report
Acrylic/Maleic Copolymer Production
Acrylic Maleic Copolymer Operating Costs & Plant Construction Costs
This report presents an economic analysis of Acrylic Acid Maleic Anhydride Copolymer production. The analysis, reflecting the economics of a United States-based plant, approaches an industrial process in that maleic anhydride is first hydrolyzed before being reacted with acrylic acid to form an Acrylic/Maleic Copolymer that is usually employed in detergents.
The report provides a comprehensive study of Acrylic Maleic Copolymer production and related Acrylic Maleic Copolymer production cost, covering three key aspects: a complete description of the Acrylic Maleic Copolymer production process examined; an in-depth analysis of the related Acrylic Maleic Copolymer plant capital cost (Capex); and an evaluation of the respective Acrylic Maleic Copolymer plant operating costs (Opex).
The Acrylic Maleic Copolymer 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 Maleic Copolymer 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 Maleic Copolymer 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 two major sections: (1) Reaction and (2) Finishing.
Reaction. Maleic anhydride is hydrolyzed and partially neutralized by a sodium hydroxide solution, resulting in a mixture of water, maleic acid, and sodium maleate. This solution is sent to the polymerization reactor, a batch reactor continuously mixed. Acrylic acid, and other chemicals (e.g., initiators and additives) are fed dropwise into the reactor, maintained at about 100 °C and 5 bar. At the end of the reaction, reducing agents can be added to terminate the copolymerization, and a sodium hydroxide solution neutralizes the system. Finally, the concentrated polymer solution goes to Finishing steps (drying and packing).
Finishing. Leaving the reactor, the polymer aqueous solution is transferred to a drying system for forming granules: it is mixed with surfactants and inorganic electrolytes and sprayed into a countercurrent spray-drying tower, in order to reduce the moisture content of the product to less than 8 wt%. Then, dry Acrylic Acid/Maleic Anhydride Copolymer granules are obtained, homogenized, packed, and stored.
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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 Maleic Copolymer 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 Maleic Copolymer 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 Maleic Copolymer 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 Maleic Copolymer 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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