Commodity Production Costs Report
Adipic Acid Production from KA Oil
Adipic Acid Operating Costs & Plant Construction Costs
This report presents the economics of Adipic Acid production from a mixture of cyclohexanone and cyclohexanol (known as KA oil) in the United States. The process portrayed comprises the oxidation of the KA oil with nitric acid to produce Adipic Acid. A mixture of adipic, glutaric, and succinic acids is generated as by-product.
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): ?
The process under analysis comprises two major sections: (1) KA Oxidation and (2) AA Crystallization and AGS Recovery.
KA Oxidation. The KA oil is oxidized with nitric acid in the presence of a copper/vanadium catalyst to form Adipic Acid. The oxidation reaction is extremely quick and carried out in two converters, operating at different temperatures. Nitrogen oxides and nitrogen gas are released from the reaction. While this can be viewed as nitric acid losses, NO2 and NO gases are recovered and recycled as nitric acid after an absorption step and a N2O abatement. The product generated from KA oil oxidation goes through bleaching, sending more gases to the absorber. The resulting liquid undergoes a concentration step to separate water and monobasic acids by vacuum stripping. The concentrated solution is subsequently sent to the crystallization process.
AA Crystallization and AGS Recovery. Crude Adipic Acid is obtained after a crystallization step under vacuum followed by centrifugation. This product is then re-dissolved in water, recrystallized, centrifuged, and dried, yielding pure fiber-grade Adipic Acid. Some of the mother liquor from the first centrifugation process is recycled into the KA oil converters. The remaining portion, along with the liquor generated after the second centrifugation, is treated to recover the catalysts, more nitric acid - recycled into the process - and an aqueous mixture containing adipic, glutaric, and succinic acids. This mixture is stored and later commercialized as a Liquid AGS mixture.
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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 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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