Commodity Production Costs Report
Caprolactam from Cyclohexane (Oximation with Hydroxylamine)
Caprolactam Operating Costs & Plant Construction Costs
This report presents the economics of Caprolactam production from cyclohexane located in the United States. Initially, cyclohexane is oxidized to a cyclohexanol/cyclohexanone. Then, the cyclohexanol is hydrogenated to cyclohexanone, which is submitted to an oximation reaction with hydroxylamine. Finally, the cyclohexanone oxime produced is converted to Caprolactam by Beckmann rearrangement.
The report provides a comprehensive study of Caprolactam production and related Caprolactam production cost, covering three key aspects: a complete description of the Caprolactam production process examined; an in-depth analysis of the related Caprolactam plant capital cost (Capex); and an evaluation of the respective Caprolactam plant operating costs (Opex).
The Caprolactam 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 Caprolactam 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 Caprolactam 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) cyclohexanone production; (2) oximation & Beckmann rearrangement; (3) Caprolactam purification; and (4) ammonium sulfate purification.
Cyclohexanone production. The cyclohexane is converted to a mixture of cyclohexanone and cyclohexanol by liquid-phase air oxidation in the presence of a soluble cobalt catalyst. The cyclohexanol in the mixture is converted to cyclohexanone by vapor-phase dehydrogenation in the presence of a copper-magnesium catalyst. Purified cyclohexanone is obtained after neutralization and distillation steps.
Oximation & Beckmann rearrangement. Ammonia is oxidized by oxygen in the presence of steam, yielding nitric oxide, which is absorbed in a solution. This nitric oxide is hydrogenated over a palladium catalyst, in the presence of dilute sulfuric acid, producing hydroxylammonium sulfate solution. It reacts with cyclohexanone in stirred reactors in series. The heterogeneous outlet is neutralized with ammonia. Finally, the cyclohexanone oxime is converted to Caprolactam by Beckmann rearrangement, in the presence of oleum.
Caprolactam purification. The product of rearrangement is subjected to purification steps, involving neutralization, extraction in the presence of toluene and light impurities removal. The raw Caprolactam melt is transformed into crystals that are melted, solidified on cold surface and the flakes produced are packed and sent to storage facilities.
Ammonium sulfate purification. Ammonium sulfate solution removed in neutralization steps is concentrated by means of evaporation. Then, it is crystallized, centrifuged from mother liquor and dried.
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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 Caprolactam 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 Caprolactam 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 Caprolactam 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 Caprolactam 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 Caprolactam Production Cost Reports
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Details: 180 kta United States-based plant | Q3 2024 | 107 pages | Issue E | From $1,199 USD
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Details: 180 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $1,199 USD
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This report presents the cost associated with a plant located in the United States producing Caprolactam from butadiene, carbon monoxide, hydrogen, and ammonia. The process under analysis involves the following steps: reaction of carbon monoxide with butadiene; hydrocarbonylation; amination and cyclization.
Details: 180 kta United States-based plant | Q3 2024 | 107 pages | Issue C | From $1,499 USD
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