Commodity Production Costs Report
Butanediol Production from Acetylene
Butanediol Operating Costs & Plant Construction Costs
This report presents the economics of an 1,4-Butanediol (BDO) production process from acetylene and formaldehyde in the United States. In this process, acetylene initially reacts with formaldehyde by addition, forming 1,4-butynediol. The butynediol is then hydrogenated to produce BDO. It is a typical acetylene-based Reppe process.
The report provides a comprehensive study of Butanediol production and related Butanediol production cost, covering three key aspects: a complete description of the Butanediol production process examined; an in-depth analysis of the related Butanediol plant capital cost (Capex); and an evaluation of the respective Butanediol plant operating costs (Opex).
The Butanediol 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 Butanediol 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 Butanediol 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 three major sections: (1) Addition; (2) Hydrogenation; and (3) Purification.
Addition. Formaldehyde, pressurized acetylene, and caustic soda are fed to the Addition Reactor, along with catalyst and product streams recovered downstream, yielding a butynediol solution. The reactor effluent passes through a catalyst recovery area and then routed to a butynediol column to remove impurities. The bottom stream, containing butynediol, is sent to the hydrogenation section.
Hydrogenation. The butynediol solution is then fed to a fixed bed reactor, along with a pressurized hydrogen stream, where the main hydrogenation takes place, generating Butanediol. This reactor operates in hydrogen cycle gas mode. The unconverted butynediol is hydrogenated in another fixed-bed reactor, operating at slightly higher temperatures and without recirculating hydrogen. The reactor effluent is separated in a liquid stream, which is sent to a distillation train downstream, and a gas stream, comprising predominantly hydrogen, which is partly recycled, and partly disposed as off-gas.
Purification. In the first column of the distillation train, low boilers compounds are removed as overheads and discharged as waste. The bottom stream is directed to a drying column to remove water from the top and Butanediol as a bottom stream. The bottom is sent to a heavy ends removal, from where the top stream is sent to Butanediol purification, which generates a side stream of purified Butanediol that is sent to storage.
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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 Butanediol 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 Butanediol 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 Butanediol 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 Butanediol 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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