Commodity Production Costs Report

Caprolactam Production from Phenol

Caprolactam Operating Costs & Plant Construction Costs

180 kta United States-based plant | 107 Pages | Issue E | Q3 2024
Starting at $1,199 USD | See Report Editions Prices

This feasibility study examines the economics of a process producing Caprolactam from phenol located in the United States. Initially, phenol is hydrogenated to form cyclohexanone. The cyclohexanone is then 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): ?

Caprolactam Production Cost Report Process Schematic

The process under analysis comprises 4 major sections: (1) Cyclohexanone production; (2) Oximation & Beckmann rearrangement; (3) Caprolactam purification; and (4) Ammonium sulfate recovery.

Cyclohexanone production. Fresh phenol is distilled, removing heavy impurities. It is fed to stirred reactors operating in series with compressed hydrogen. The reaction takes place in the liquid phase, catalyzed by palladium on carbon, yielding cyclohexanone. Purified cyclohexanone is obtained after the reactor outlet is passed through centrifugation and distillation steps.

Oximation & Beckmann rearrangement. Ammonia is oxidized yielding nitric oxide, which is absorbed in water and then hydrogenated over a palladium catalyst, in the presence of dilute sulfuric acid, producing hydroxylammonium sulfate solution. The hydroxylammonium sulfate solution reacts with purified cyclohexanone in stirred reactors, in toluene solvent, to form cyclohexanone oxime. The solution containing cyclohexanone oxime is then distilled for the removal of toluene solvent. 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 recovery. Ammonium sulfate solution removed in neutralization steps is concentrated by means of evaporation. Then, it is crystallized, centrifuged and dried.

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Features
  • Production Process Information
  • Process Consumptions
  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
  • Production Costs Datasheet
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 80 Pages | 22 Tables | 9 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
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 90 Pages | 28 Tables | 13 Images

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Updated with Q3 2024 Data

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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
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  • 107 Pages | 34 Tables | 22 Images
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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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