Commodity Production Costs Report
Adipic Acid Production from Benzene and Propylene
Adipic Acid Operating Costs & Plant Construction Costs
This feasibility study assesses the production of Adipic Acid from benzene and propylene in the United States. In the process depicted, phenol is initially produced from benzene and propylene by means of alkylation, oxidation and cleavage. Then, phenol is hydrogenated to produce KA oil, which is then oxidized with nitric acid to produce Adipic Acid.
The report provides a comprehensive study of Adipic Acid production and related Adipic Acid production cost, covering three key aspects: a complete description of the Adipic Acid production process examined; an in-depth analysis of the related Adipic Acid plant capital cost (Capex); and an evaluation of the respective Adipic Acid plant operating costs (Opex).
The Adipic 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 Adipic 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 Adipic 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): ?
Products
Adipic Acid. Adipic Acid is one of the most commercially important aliphatic dicarboxylic acids, produced on a very large scale at several locations worldwide.
Acetone. Acetone, also known as 2-propanone, is the simplest ketone. It is used as solvent for a wide range of organic compounds (e.g. oils, fats, resins, waxes and gums). It is also used as feedstock for the production of several chemicals, such as methyl methacrylate, bisphenol A, and methyl isobutyl ketone. The main source of acetone is the process for phenol production from cumene, which generates acetone as by-product at an approximate ratio for 0.6 kg of acetone per kg of phenol. Industrial consumers of acetone usually receive shipments in large containers made of carbon steel, tank trucks made of stainless steel or aluminum, or rail tank cars made of carbon steel or aluminum. International shipments by sea are usually made in steel barges and amount at least 2,000 metric tons.
Raw Materials
Propylene. Propylene, the main raw material consumed, is a colorless gas at room temperature. It is a low-boiling, flammable, and highly volatile gas, with molecular formula C3H6. Propylene reacts vigorously with oxidizing materials. It may be mildly irritating to the nose, throat, and respiratory tract; propylene has low acute toxicity from inhalation. PG Propylene has been mainly produced as ethylene manufacturing co-product (via steam cracking of paraffinic hydrocarbons) and by-product of petroleum refining (separation from refinery gas). Most recently, amid a tight propylene market, new and novel lower-cost chemical processes for on-purpose propylene production have emerged.
Benzene. Benzene (C6H6) is a flammable and volatile liquid. As the most simple aromatic hydrocarbon, it is used as an intermediate to produce many important chemicals, such as styrene (raw material for polystyrene and synthetic rubber), cyclohexane (used in nylon production), alkylbenzenes (used in detergent industry), aniline (used to produce dyes and polyurethanes), and chlorobenzenes. Also, benzene is used to produce pharmaceuticals, specialty chemicals, plastics, and pesticides. It occurs naturally in crude oil and coal tar.
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Adipic 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 Adipic 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 Adipic 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 Adipic 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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Other Adipic Acid Production Cost Reports
Bio-Adipic Acid Production from Glucose (Chemical Catalytic Process)
This report shows a feasibility study of Bio-Adipic Acid production from glucose syrup in a plant located in the United States. The route examined is a two-step catalytic process similar to Rennovia process. In this process, glucose is first oxidized to produce glucaric acid, which is then hydrogenated to produce Adipic Acid.
Details: 150 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $799 USD
Bio-Adipic Acid Production from Glucose (Fermentation Process)
This report assesses the economics of production of bio-based Adipic Acid. The process examined in this report is a fermentation process similar to BioAmber process, in which glucose is fermented to adipic acid. The process under analysis assumes a plant located in the United States.
Details: 150 kta United States-based plant | Q3 2024 | 107 pages | Issue C | From $799 USD
Adipic Acid Production from Benzene (Cyclohexane Intermediate)
This report presents the economics of Adipic Acid production from benzene in the United States using a two-stage oxidation process similar to Invista process. In this process, benzene is hydrogenated to cyclohexane, which is then oxidized to produce adipic acid with KA oil as intermediate.
Details: 350 kta United States-based plant | Q3 2024 | 107 pages | Issue E | From $1,499 USD
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Other Related Production Cost Reports
Propylene Production from Propane (Moving-Bed Reactor)
This study presents the economics of Polymer Grade (PG) Propylene production from propane. The process consists in the dehydrogenation of propane, carried out in a moving-bed reactor, similar to UOP Oleflex. The economic analysis performed assumes a plant located in the United States.
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Benzene Production from Pygas (Hydrodealkylation Process)
This analysis presents the economics of Benzene production from pyrolysis gasoline (pygas) in the United States using a typical hydrodealkylation process. Initially, pygas is fractionated into 3 hydrocarbon cuts. The C6-C8 fraction is then directed to the hydrodealkylation step, in which the aromatics content in the process stream are converted into benzene
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This report presents the economics of Adiponitrile production from adipic acid and ammonia. In the process examined, adipic acid is reacted with ammonia in the presence of a phosphoric acid based catalyst to generate adiponitrile. The economic analysis performed assumes a plant located in the United States.
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Fiber-Grade Adipic Acid Production from Crude Adipic Acid
This report presents the economics of high-purity Adipic Acid production starting from a crude adipic acid stream from a conventional two-stage oxidation process (similar to Invista technology). The crude stream passes through a series of purification steps that include centrifugation, crystallization and drying. The process under analysis assumes a plant located in the United States.
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Benzene Production from Pygas (Extractive Distillation Process)
This report examines the costs related to Benzene production from pyrolysis gasoline (pygas) in the United States using a typical extractive distillation process. Initially, pygas is fractionated into 3 hydrocarbon cuts. The C6s fraction is then fed to an extractive distillation system, using N-formylmorpholine (NFM) as solvent. to recover benzene.
Details: 250 kta United States-based plant | Q3 2024 | 107 pages | Issue C | From $799 USD
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