Commodity Production Costs Report

Butyraldehyde from Propylene and Syngas (N/Iso Ratio of 10:1)

Butyraldehyde Operating Costs & Plant Construction Costs

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

This feasibility study approaches n-Butyraldehyde production from propylene and syngas, assuming a plant located in the United States. The process under analysis is a propylene hydroformylation similar to the LP OXO technology jointly developed by JM Davy and Union Carbide, employing Selector 10 catalyst. The production ratio of n- to iso-butyraldehyde is about 10.

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

The Butyraldehyde 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 Butyraldehyde 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 Butyraldehyde 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): ?

Butyraldehyde Production Cost Report Process Overview
Products

n-Butyraldehyde. n-Butyraldehyde is a key intermediate used in the manufacture of plasticizers, resins, and solvents. It is produced via the oxo process from propylene. It is a highly reactive aldehyde stored as a liquid and widely used in industrial organic synthesis.

Isobutyraldehyde. Isobutyraldehyde is a saturated aliphatic C4 aldehyde. Like other aldehydes, isobutyraldehyde finds widespread use as a chemical intermediate, mainly in the production of primary solvents and rubber antioxidants. Most of commercial production of this aldehyde is based on the Oxo Reaction of propylene hydroformulation of propylene, which generates n-butyraldehyde (precursor of 2-Ethylhexanol) and isobutyraldehyde as a side-product. Handling and storage of both n- and isobutyraldehyde is made using stainless steel, baked phenolic lined steel, or aluminum.

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.

Synthesis Gas. Synthesis gas is a gas mixture mainly composed of carbon monoxide (CO) and hydrogen (H2). It is a raw material for the production of various products, such as methanol, hydrogen, carbon monoxide, dimethyl ether, oxo alcohols and many other chemicals. Syngas may be produced from both fossil sources (e.g. coal, petroleum or natural gas) and renewable materials, such as biomass or wood. Synthesis gas is produced industrially via different routes including steam methane reforming, partial oxidation, and dry reforming. Its composition can significantly vary from the production method used.

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  • Production Process Information
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 80 Pages | 22 Tables | 9 Images

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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
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 90 Pages | 28 Tables | 13 Images

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Table of Contents


Features
  • 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
  • See All Features

  • 107 Pages | 34 Tables | 22 Images
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  • Updated with Q3 2024 Data
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Content Highlights

Plant Capital Cost Summary

Summary outlining the capital cost required for building the Butyraldehyde 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 Butyraldehyde 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 Butyraldehyde 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 Butyraldehyde 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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