Commodity Production Costs Report

Hexamethylene Diisocyanate from HMDA (Phosgenation Process)

HDI Operating Costs & Plant Construction Costs

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

This study provides the economics of a phosgenation process for Hexamethylene Diisocyanate (HDI) production from hexamethylene diamine (HMDA) in the United States. In this process, HMDA reacts with phosgene to produce HDI. The phosgene used is generated from chlorine and carbon monoxide in an on-site unit. Hydrogen chloride (HCl) is generated as by-product.

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

The HDI 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 HDI 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 HDI 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): ?

HDI Production Cost Report Process Schematic

The process under analysis comprises three major sections: (1) Phosgene Generation; (2) HMDA Phosgenation and (3) Purification.

Phosgene Generation. Carbon monoxide and chlorine gas are mixed and fed to a vertical shell and tube reactor, where such components react generating phosgene. The reactor is filled with activated carbon, which serve as catalyst. The effluent from the reactors is forwarded to the phosgenation section.

HMDA Phosgenation. Phosgene from the phosgene generation and phosgene recovered downstream are fed to an absorber. In the absorber the phosgene content in the gaseous feed stream is absorbed in cold ortho-dichlorobenzene (ODCB). Part of the overhead from the absorber, mostly containing HCl by-product is fed to a jacketed agitated vessel along with hexamethylenediamine (HMDA). In this reactor, the HMDA and the HCl react forming an HMDA.HCl slurry in ODCB. Such slurry is then subjected to a phosgenation reaction, carried out in a continuous two-step tank-shaped reactor. The remaining part of the overhead from the absorber is fed to a HCl recovery system, where a 32 wt% hydrochloric acid stream is obtained as by-product.

Purification. The product stream from the phosgenation reactors is initially stripped against nitrogen, for the removal of remaining phosgene and HCl content. The product stream is then passed through a solvent recovery step, so that most of the ODCB is separated and recycled. The stream rich in HDI is then passed through a series of distillation columns for the removal of heavy impurities, yielding high-purity HDI.

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  • 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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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 HDI 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 HDI 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 HDI 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 HDI 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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