Commodity Production Costs Report

FDCA Production from Glucose

FDCA Operating Costs & Plant Construction Costs

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

This report presents the economics of 2,5-Furandicarboxylic Acid (FDCA) production from glucose syrup via a furan process similar to Avantium YXY technology. Initially, glucose is enzymatically isomerized into fructose, which is dehydrated in the presence of methanol, yielding methoxymethylfurfural (MMF). Finally, MMF is oxidized to FDCA. The economic analysis assumes a plant constructed in the United States.

The report provides a comprehensive study of FDCA production and related FDCA production cost, covering three key aspects: a complete description of the FDCA production process examined; an in-depth analysis of the related FDCA plant capital cost (Capex); and an evaluation of the respective FDCA plant operating costs (Opex).

The FDCA 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 FDCA 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 FDCA 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): ?

FDCA Production Cost Report Process Schematic

The process under analysis comprises three major sections: (1) Furans Production; (2) MMF Purification; and (3) FDCA Production.

Furans production. The glucose content of the feed is first enzymatically isomerized to fructose, and the effluent is passed through ion-exchange resins to separate unreacted glucose from the fructose. The former is recycled to the isomerization reactor and the latter is sent to the furans conversion reactor. There, crystallized fructose is solubilized with a 95 wt.% methanol aqueous solution and sulfuric acid. The reaction is conducted at 50 bars and 200ºC. Fructose is dehydrated to hydroxyl methyl furan (HMF) and, due to the excess of methanol, most HMF is converted to MMF, which is more stable than HMF.

MMF purification. The reactor effluent is then sent to a distillation system to recover the solvent and separate the MMF from other impurities. Methanol and water are recovered and returned to the furans conversion area, while methyl levulinate is recovered as a byproduct. Also, a heavies stream is recovered to be used as boiler fuel, and finally, purified MMF is recovered and directed to the FDCA production area.

FDCA production. Purified MMF is mixed with acetic acid solvent and catalyst in the oxidation reactor to be converted to FDCA. This stream is filtered to recover crude FDCA. The acetic-acid-rich liquid is purified using two distillation columns. Catalyst is also recovered, but it must be reactivated before being recycled to the process. Crude FDCA is mixed with water and hydrogen in a hydrogenation reactor, where impurities are removed. The effluent from the reactor is crystallized, and purified FDCA is recovered from the solid materials. The liquid effluent is a waste stream.

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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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  • Updated with Q3 2024 Data
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Content Highlights

Plant Capital Cost Summary

Summary outlining the capital cost required for building the FDCA 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 FDCA 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 FDCA 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 FDCA 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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This report presents the costs associated with the construction of a plant producing FDCA from raw sugar (sucrose) in Germany. Initially, sucrose is hydrolyzed into glucose and fructose and the glucose obtained is enzymatically isomerized into fructose. It is then dehydrated in ionic liquid medium, yielding hydroxymethylfurfural, which is finally oxidized to FDCA. The process examined is based in a non-commercial route.

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Details: 270 kta United States-based plant | Q3 2024 | 107 pages | Issue C | From $799 USD

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This report concerns the economics of 2,5-Furandicarboxylic Acid (FDCA) production via hydroxymethylfurfural (HMF) oxidation. The FDCA generated in this reaction is recovered in liquid form via high temperature distillation. The economic analysis is also based on a plant located in the United States.

Details: 270 kta United States-based plant | Q3 2024 | 107 pages | Issue D | From $999 USD

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