Commodity Production Costs Report

FDCA Production from Raw Sugar

FDCA Operating Costs & Plant Construction Costs

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

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.

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) Fructose Obataining; (2) Fructose Dehydration; and (3) FDCA Production and Purification.

Fructose Obtaining. Raw sugar is diluted with a hot water stream, forming a sucrose solution that is fed to ion exchangers, yielding a solution comprising glucose and fructose, which is sent to the Glucose Isomerization reactor. In this reactor, glucose is enzymatically isomerized to fructose. The reactor effluent is routed to an evaporator to remove excess water, and then to a chromatographic separator, a set of ion exchange resins that separates fructose, directed to a crystallizer, from glucose, which is recycled to the reactor.

Fructose Dehydration. Fructose slurry form the crystallizer is dissolved in an ionic liquid and fed to the Dehydration Reactor, a heated column where it is converted to HMF. Methyl isobutyl ketone (MIBK) is fed into the reactor in counter-current mode, continuously extracting formed HMF from the reaction phase. The extractant phase is sent to HMF Separation, where MIBK is recovered to the reactor and HMF is purified, while the ionic liquid phase is routed to a column to separate water from fructose, which is recycled to the reactor.

FDCA Production and Purification. Purified HMF 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, centrifugated and dried, and finally purified FDCA is recovered sent to storage.

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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
  • See All Features

  • 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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