Commodity Production Costs Report
Butyl Acrylate Production from Propylene and Butanol
Butyl Acrylate Operating Costs & Plant Construction Costs
This study concerns the production of n-Butyl Acrylate, starting from propylene and n-butanol. Chemical grade propylene is oxidized to acrolein and then to acrylic acid, which is then fed to an esterification reaction, along with n-butanol to generate Butyl Acrylate. The economic analysis performed is based on a plant located in the United States.
The report provides a comprehensive study of Butyl Acrylate production and related Butyl Acrylate production cost, covering three key aspects: a complete description of the Butyl Acrylate production process examined; an in-depth analysis of the related Butyl Acrylate plant capital cost (Capex); and an evaluation of the respective Butyl Acrylate plant operating costs (Opex).
The Butyl Acrylate 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 Butyl Acrylate 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 Butyl Acrylate 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 four major sections: (1) Reaction and quench; (2) Acrylic Acid recovery; (3) Esterification; and (4) Product Purification.
Reaction and quench. Chemical grade (CG) propylene mixed with steam and air is fed to a two-step oxidation reaction system. Firstly, propylene is oxidized to acrolein, which is then oxidized to acrylic acid. The effluent is sent to a quench tower, where the acrylic acid formed is absorbed in water. This solution is sent to next section. Part of the residual gas from the top of the quench tower is recycled to the first reactor, and the remainder is incinerated.
Acrylic acid recovery. The acrylic acid solution from quench is purified by extraction with an organic solvent and distillation, removing water, light and heavy ends.
Esterification. Acrylic acid and a small excess of n-butanol are fed to reaction system. In addition, water is continuously removed from reaction system. The esterification reaction is carried out in two consecutive reactors - the second one equipped with a column for water removal. An organic acid (e.g. benzene sulfonic acid) is employed as catalyst. Yields of 95-98% based on acrylic acid are achieved.
Product Purification. The reactor effluent, a mixture containing Butyl Acrylate, unreacted butanol, water and some acrylic acid, is passed through a series of columns. Initially, most of acrylic acid is removed from the product stream. This phase is washed to remove butanol and traces of acid. Then, the washed butyl acrylate is dried and further purified in two columns, which separates residual butanol and organic heavy wastes.
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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 Butyl Acrylate 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 Butyl Acrylate 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 Butyl Acrylate 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 Butyl Acrylate 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 Butyl Acrylate Production Cost Reports
Butyl Acrylate Production from Acrylic Acid and Butanol
This report approaches the production of n-Butyl Acrylate from acrylic acid and n-butanol. The process examined is similar to the Synthomer's Butyl Acrylate Process. In this process acrylic acid and n-butanol are directly converted to Butyl Acrylate via an esterification reaction catalyzed by p-Toluene Sulfonic Acid. The economic analysis performed assumes a plant located in the United States.
Details: 150 kta United States-based plant | Q3 2024 | 107 pages | Issue A | From $799 USD
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