Commodity Production Costs Report
Isoprene Production from Isobutylene
Isoprene Operating Costs & Plant Construction Costs
This report presents the economics of Isoprene production from isobutylene (contained in a C4 cut stream) and formaldehyde in the United States via a typical two-step carbonylation process. Initially, isobutylene is reacted with formaldehyde forming 4,4-dimethyl-1,3-metadioxane (4-4 DMD). This intermediate is then cracked, producing Isoprene.
The report provides a comprehensive study of Isoprene production and related Isoprene production cost, covering three key aspects: a complete description of the Isoprene production process examined; an in-depth analysis of the related Isoprene plant capital cost (Capex); and an evaluation of the respective Isoprene plant operating costs (Opex).
The Isoprene 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 Isoprene 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 Isoprene 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) DMD Synthesis; (2) DMD Decomposition and (3) Separation & Purification.
DMD Synthesis. In the first section, isobutylene (present in a C4 cut stream) reacts with formaldehyde in a stirred reactor, in the presence of a dilute sulfuric acid solution used as catalyst. This reaction yields dioxanes – mainly 4,4-dimethyl 1,3-metadioxane (DMD), an intermediate for Isoprene production downstream. After the reaction, the mixture containing the dioxanes formed passes through a sequence of separation steps, so that a mixed C4s stream, a formaldehyde-containing aqueous phase, and impurities are separated from the dioxane.
DMD Decomposition. The DMD stream obtained is vaporized, superheated and then subjected to a cracking reaction on a solid catalyst (supported phosphoric acid) in the presence of steam. The DMD cracking yields Isoprene, while the other dioxanes are decomposed into Isoprene isomers.
Separation & Purification. At this point, unreacted DMD, isobutylene and formaldehyde are separated from the Isoprene produced and recycled to the process by means of a separation train comprising extractors and distillation columns.
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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 Isoprene 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 Isoprene 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 Isoprene 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 Isoprene 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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Details: 50 kta United States-based plant | Q3 2024 | 107 pages | Issue C | From $999 USD
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Propylene Production from Butenes
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