Commodity Production Costs Report

Acrylonitrile Production from Propylene (Fluidized Bed Ammoxidation)

Acrylonitrile Operating Costs & Plant Construction Costs

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

This report presents the economics of Acrylonitrile production from chemical grade (CG) propylene in the United States. The process reviewed is a propylene ammoxidation technology using fluidized bed reactor, in which propylene reacts with ammonia, producing Acrylonitrile, and generating acetonitrile and hydrogen cyanide as by-products.

The report provides a comprehensive study of Acrylonitrile production and related Acrylonitrile production cost, covering three key aspects: a complete description of the Acrylonitrile production process examined; an in-depth analysis of the related Acrylonitrile plant capital cost (Capex); and an evaluation of the respective Acrylonitrile plant operating costs (Opex).

The Acrylonitrile 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 Acrylonitrile 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 Acrylonitrile 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): ?

Acrylonitrile Production Cost Report Process Schematic

The process under analysis comprises four major sections: (1) Ammoxidation; (2) Separation; (3) Acetonitrile recovery; and (4) Purifcation.

Ammoxidation. CG propylene, ammonia and air are fed to a reactor, where an ammoxidation reaction occurs in the vapor phase, over fluidized catalysts. The reaction effluent comprises Acrylonitrile, hydrogen cyanide, acetonitrile, carbon oxides, as well as unconverted propylene and ammonia.

Separation. The reactor effluent is sent to a quench column, where unreacted ammonia is neutralized with sulfuric acid. The quenched gas is transferred to the nitrile absorber, where Acrylonitrile is absorbed and transferred to the recovery column. In the recovery column, acetonitrile and water are separated from Acrylonitrile and hydrogen cyanide.

Acetonitrile recovery. A liquid side stream from the recovery column, containing a mixture of acetonitrile and water, is sent to the acetonitrile stripper, where the it is distilled under vacuum to separate water and heavy organics. The acetonitrile-water azeotrope obtained is then distilled at high pressure into three streams: a bottom product comprising heavy impurities; an aqueous stream containing also some acetonitrile as column overhead, which is recycled to the acetronitrile stripper; and a side stream containing high-purity acetonitrile.

Purifcation. The organic phase from the recovery column is fed into the HCN column for the separation of HCN from Acrylonitrile. The Acrylonitrile-rich stream is transferred into the Acrylonitrile purification column, where column overhead gaseous stream flows into a condenser. The condensate is then sent to a decanter, in which the denser phase (mainly water) is withdrawn from decantation drum and recycled to the recovery column. The less dense phase is transferred to the acrylonitrile purifcation column, where fiber-grade Acrylonitrile product is withdrawn as a sidestream.

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  • Process Consumptions
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 80 Pages | 22 Tables | 9 Images

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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 Acrylonitrile 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 Acrylonitrile 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 Acrylonitrile 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 Acrylonitrile 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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