Commodity Production Costs Report
Caprolactam Production from Toluene
Caprolactam Operating Costs & Plant Construction Costs
This study reviews the economics of a process for Caprolactam production from toluene. Initially, toluene is oxidized to benzoic acid, which is then hydrogenated to hexahydrobenzoic acid. The hexahydrobenzoic acid is reacted with nitrosyl sulfuric acid and oleum for caprolactam production. The economic analysis performed is based on a plant constructed in the United States.
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): ?
Product
Caprolactam. Caprolactam is the key raw material used in the production of nylon 6 fibers and resins, essential in textiles, carpets, and engineering plastics. Its high tensile strength and durability make it invaluable in automotive and industrial applications. Caprolactam is produced via the cyclohexanone oxime process. It is stored as solid flakes or granules and remains in high demand due to the growing global need for synthetic fibers and resins.
Raw Material
Toluene. Toluene (also known as Methylbenzene) is an aromatic hydrocarbon mainly used as an industrial feedstock and as solvent. A significant part of toluene production is blended directly into gasoline pools. Other major use of this chemical is in the manufacture of the more valuable benzene, through hydrodealkylation. Most of toluene is produced via catalytic reforming of refinery streams (C6–C9 naphthas), along with benzene, xylenes, and C9-aromatics.
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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
Caprolactam from Cyclohexane (Oximation with Hydroxylamine)
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.
Details: 180 kta United States-based plant | Q3 2024 | 107 pages | Issue D | From $1,199 USD
Caprolactam Production from Phenol
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.
Details: 180 kta United States-based plant | Q3 2024 | 107 pages | Issue E | From $1,199 USD
Caprolactam Production from Butadiene and Hydrogen Cyanide
This feasibility study shows the economics of a Caprolactam production process from butadiene and hydrogen cyanide based on an industrial plant located in the United States. Hexamethylenediamine (HMDA) is generated as by-product in the process under analysis.
Details: 180 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $1,199 USD
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Other Related Production Cost Reports
Nylon 6 Production from Caprolactam (Batch Process)
This report presents the economics of Nylon 6 production from caprolactam. The typical process analyzed consists of a batch ring-opening polymerization of caprolactam via the hydrolytic mechanism. The economic assessment assumes a plant located in the United States.
Details: 65 kta United States-based plant | Q3 2024 | 107 pages | Issue A | From $799 USD
Toluene Production from Pygas
This study presents the economics of Toluene production from pyrolysis gasoline (pygas) in the United States using a typical liquid-liquid extraction process.
Details: 400 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $799 USD
Nylon 6 Production from Caprolactam (Continuous Process)
This report presents the economics of Nylon 6 production from caprolactam in the United States. The process examined is a typical continuous ring-opening polymerization of caprolactam via the hydrolytic mechanism, carried out in two stages, similar to technologies developed/licensed by Thyssenkrupp (Uhde Inventa-Fischer) and Air Liquide (Lurgi Zimmer). An aminoacid is the intermediate for condensation.
Details: 100 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $799 USD
Toluene Production from Reformate
This report presents the economics of Toluene production from reformate. The reformate is submitted to a typical sulfolane liquid-liquid extraction, giving a mixture of aromatics, which is further processed to yield pure Toluene. Benzene and mixed xylenes are produced as by-products. The economic analysis presented is based on a plant constructed in the United States.
Details: 350 kta United States-based plant | Q3 2024 | 107 pages | Issue A | From $799 USD
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