Commodity Production Costs Report

Caprolactam Production from Benzene

Caprolactam Operating Costs & Plant Construction Costs

180 kta United States-based plant | 107 Pages | Issue A | Q3 2024
Starting at $1,499 USD | See Report Editions Prices

This report presents the economics of Caprolactam production from benzene located in the United States. Initially, benzene is hydrogenated to cyclohexane, which is oxidized to cyclohexanone. Then, the cyclohexanone undergoes an oximation reaction with hydroxylamine. Finally, the oxime produced is rearranged to Caprolactam.

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): ?

Caprolactam Production Cost Report Process Schematic

The process under analysis comprises 4 major sections: (1) Benzene hydrogenation; (2) Cyclohexane oxidation; (3) Oximation & Beckmann Rearrangement; and (4) Ammonium Sulfate Purification.

Benzene hydrogenation. First, dried benzene is reacted with hydrogen in two steps, in the presence of platinum-based and zinc oxide catalysts, to form cyclohexane. The intermediate is purified in two columns and hydrogen is recycled to reactor.

Cyclohexane oxidation. The cyclohexane is converted to a mixture of cyclohexanone and cyclohexanol by liquid-phase air oxidation in the presence of a soluble cobalt catalyst, as indicated below. The cyclohexanol in the mixture is converted to cyclohexanone by vapor-phase dehydrogenation in the presence of a copper-magnesium catalyst.

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. The product of rearrangement is purified in some equipments, involving neutralization, extraction in the presence of toluene and distillation. The caprolactam melt is solidified and converted into flakes.

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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  • Production Process Information
  • Process Consumptions
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 90 Pages | 28 Tables | 13 Images

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Table of Contents


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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
  • Plant Cost Breakdowns
  • Plant Capacity Assessment
  • Process Flow Diagrams
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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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