Commodity Production Costs Report
Hydrochloric Acid Production from Hydrogen and Chlorine
Hydrochloric Acid Operating Costs & Plant Construction Costs
This study analysis the economics of Hydrochloric Acid (HCl) production from hydrogen and chlorine in the United States. The process examined is a typical synthesis of Hydrogen Chloride via the direct reaction of the elements. In this process, hydrogen and chlorine, undergo a direct reaction forming hydrogen chloride, which is subsequently passed through an absorber to produce a 35 wt% hydrochloric acid as final product.
The report provides a comprehensive study of Hydrochloric Acid production and related Hydrochloric Acid production cost, covering three key aspects: a complete description of the Hydrochloric Acid production process examined; an in-depth analysis of the related Hydrochloric Acid plant capital cost (Capex); and an evaluation of the respective Hydrochloric Acid plant operating costs (Opex).
The Hydrochloric Acid 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 Hydrochloric Acid 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 Hydrochloric Acid 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): ?

The process under analysis comprises two sections: (1) Reaction, and (2) Absorption.
Reaction. Chlorine and hydrogen are combined in a combustion chamber to produce hydrogen chloride. Slight excess of hydrogen is used to minimize the chlorine content of the product. The gas leaving the reactor is cooled before moving on to the absorption stage.
Absorption. The gaseous hydrogen chloride produced is fed to a falling film absorber, where it is absorbed in a weak acid stream to produce 35 wt% hydrochloric acid. The fraction of gas that is not absorbed in this first step is sent to a tails tower fed with demineralized water, where the aforementioned weak acid stream is formed and then recycled to the absorber.
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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 Hydrochloric Acid 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 Hydrochloric Acid 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 Hydrochloric Acid 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 Hydrochloric Acid 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
Other Hydrochloric Acid Production Cost Reports

Hydrogen Chloride Production from Hydrogen and Chlorine
This study analysis the economics of Anhydrous Hydrogen Chloride (HCl) production from hydrogen and chlorine in the United States. The process examined is a typical synthesis of Hydrogen Chloride via the direct reaction of the elements.
Details: 25 kta United States-based plant | Q3 2024 | 107 pages | Issue A | From $799 USD

Hydrochloric Acid from NaCl and Sulfuric Acid (Reactor Furnace)
This report presents the economics of Hydrochloric Acid production from sodium chloride and sulfuric acid in the USA through a typical Mannheim process in which the reaction occurs in a reactor furnace. Initially, sulfuric acid reacts with sodium chloride producing hydrogen chloride and sodium sulfate, a by-product. Subsequently, the gas is absorbed in water and Hydrochloric Acid is obtained as the final product.
Details: 15 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $799 USD

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This report presents the economics of Hydrochloric Acid (HCl) production from sodium chloride and sulfuric acid in the United States . In this process, sulfuric acid reacts with sodium chloride in a fluidized bed reactor, forming hydrogen chloride and sodium sulfate, a by-product. Subsequently, the gas is absorbed in water and Hydrochloric Acid is obtained as the final product.
Details: 15 kta United States-based plant | Q3 2024 | 107 pages | Issue C | From $799 USD
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