Commodity Production Costs Report
Butyraldehyde from Propylene and Syngas (N/Iso Ratio of 30:1)
Butyraldehyde Operating Costs & Plant Construction Costs
This report presents an economic analysis of 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 licensed by JM Davy and Dow, employing Selector 30 catalyst. The production ratio of n- to iso-butyraldehyde is about 30.
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): ?
The process under analysis comprises the following major sections: (1) hydroformylation; (2) catalyst recovery and (3) purification.
* Hydroformylation. Fresh propylene and syngas are treated to remove impurities that could poison the rhodium catalyst employed in the hydroformylation reaction. The purified raw materials, recycled reactants and recycled catalyst solution are fed to the first of two reactors operating in series. In both reactors, the propylene reacts with carbon monoxide and hydrogen at mild temperatures and low pressures, and in the presence of a homogeneous rhodium-based catalyst with an organophosphite ligand, yielding n-Butyraldehyde as main product and isobutyraldehyde by-product. The catalyst is dissolved in the high-boiling reaction by-products.
* Catalyst recovery. The liquid effluent from the hydroformylation, containing catalyst components, reaction products, unreacted propylene, as well as aldehyde products with some dissolved gases, is depressurized and fed to a falling-film evaporator. The concentrated catalyst solution obtained from evaporator is recycled to the hydroformylation area, with a small portion directed to a catalyst regeneration step. The vapor from evaporator is partially condensed and the uncondensed gas is recycled to the reactor through a compressor. The condensed liquid stream is sent to the purification steps.
* Purification. The condensed liquid stream containing the aldehydes from the catalyst recovery is directed to the first of three distillation columns for the purification of n-Butyraldehyde product. In the first column, the stabilizer column, remaining traces of dissolved gases are removed (propylene, propane, and other inert gases) and recycled to the hydroformylation. The bottom stream from the stabilizer column is fed to a second distillation column, where isobutyraldehyde is separated. In the third column, the heavy-ends column, heavies impurities are separated from the n-Butyraldehyde product (with 99 wt% purity), which is finally routed to storage facilities located outside battery limits.
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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 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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Other Butyraldehyde Production Cost Reports
Butyraldehyde from Propylene and Syngas (N/Iso Ratio of 10:1)
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.
Details: 160 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $799 USD
Butyraldehyde from Propylene and Syngas (N/Iso Ratio of 4:1)
This report concerns the costs associated with the production of n-Butyraldehyde from propylene and syngas. The process under analysis is a propylene hydroformylation similar to the technology jointly developed by Rhodia (former Rhône-Poulenc) and Ruhrchemie. The economic analysis presented assumes a plant located in the United States.
Details: 160 kta United States-based plant | Q3 2024 | 107 pages | Issue C | From $799 USD
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