Commodity Production Costs Report
IPDI Production from Isophorone and Chlorine
IPDI Operating Costs & Plant Construction Costs
This report presents the economics of Isophorone Diisocyanate (IPDI) from isophorone and chlorine in the United States. In the process examined, isophorone is reacted with hydrogen cyanide, generating IPN. IPN obtained is then reacted with ammonia to form IPNI, which is hydrogenated with more ammonia to yield IPDA. Finally, IPDA reacts with phosgene to produce IPDI. The phosgene used is generated from chlorine and carbon monoxide.
The report provides a comprehensive study of IPDI production and related IPDI production cost, covering three key aspects: a complete description of the IPDI production process examined; an in-depth analysis of the related IPDI plant capital cost (Capex); and an evaluation of the respective IPDI plant operating costs (Opex).
The IPDI 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 IPDI 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 IPDI 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 three major sections: (1) Isophorone Hydrocyanation; (2) Isophorone nitrile (IPN) Amino-hydrogenation; and (3) Isophorone Diamine (IPDA) Phosgenation.
Isophorone Hydrocyanation. Initially, fresh and recycled isophorone are fed to a plug flow tubular reactor, along with hydrogen cyanide (HCN). The reaction is carried out in the presence of caustic soda, under atmospheric pressure. Excess of isophorone is used to avoid undesirable reactions (between HCN and the carbonyl group of isophorone). IPN is recovered from the hydrocyanation effluent after washing, distillation and evaporation steps. Caustic soda and unreacted isophorone are returned to the hydrocyanation.
IPN Amino-hydrogenation. The IPN obtained is mixed with excess ammonia and reacted to form isophorone nitrile imine (IPNI) in the presence of gamma-aluminum oxide catalyst. The product of the imination reaction, comprising IPNI, IPN and unreacted ammonia, is fed to the amino-hydrogenation reactors along with hydrogen and more ammonia. This reaction step occurs in the presence of conventional hydrogenation catalysts, yielding IPDA. Unreacted hydrogen and ammonia are separated from the amination effluent and recycled. The IPDA-rich stream is subsequently submitted to distillation and evaporation steps for purification.
IPDA Phosgenation. IPDA and phosgene are vaporized and superheated, then they are fed to the reactors.The mixture is kept at high temperatures for a short time in order to avoid the generation of side products or the decomposition of phosgene. Solvent is used to condense the isophorone diisocianate formed. The liquid stream is further treated to remove the solvent, as well as light and heavy ends. Finally, the purified IPDI product is obtained. The gaseous effluent obtained after liquefaction of IPDI is further treated, in order to recover phosgene and hydrogen chloride.
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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 IPDI 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 IPDI 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 IPDI 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 IPDI 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 IPDI Production Cost Reports
IPDI Production from Isophorone and Urea
This study examines the economics of Isophorone Diisocyanate (IPDI) production from isophorone and urea in the United States. This process is a non-phosgene route. In the non-phosgene process, IPDA reacts with urea and butanol generating a carbamate intermediate. Then, the carbamate is thermally cracked producing IPDI.
Details: 15 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $799 USD
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