Commodity Production Costs Report
KA Oil Production
KA Oil Plant Capital & Operating Cost Analysis | United States | Q1 2026
This report presents the economics of KA oil production from cyclohexane. The process examined is similar to the one developed by Invista. In this process, cyclohexane is initially oxidized with air to produce a mixture of cyclohexanone and cyclohexanol (also referred to as ketone-alcohol oil - KA oil).
The report provides a comprehensive study of KA Oil production and related KA Oil production cost, covering three key aspects: a complete description of the KA Oil production process examined; an in-depth analysis of the related KA Oil plant capital cost (Capex); and an evaluation of the respective KA Oil plant operating costs (Opex).
The KA Oil 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 KA Oil 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 KA Oil plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
The process under analysis comprises two major sections: (1) Oxidation; and (2) Purification.
Oxidation. Initially, cyclohexane is fed to the first of several staged air oxidation vessels, along with meta-boric acid. The cyclohexane is oxidized in the liquid-phase to cyclohexyl hydroperoxide (CHHP). In the presence of boric acid, the cyclohexyl hydroperoxide is trapped as cyclohexyl perborate ester, which in turn reacts with cyclohexane yielding borate ester and cyclohexanol. The borate ester formed is relatively stable, in such a way that the generation of undesired by-products is minimized. Next, the ester is hydrolyzed, yielding cyclohexanol and boric acid, in organic and aqueous phases, respectively. Subsequently, CHHP still present in the oxidation product is decomposed by another oxidation reaction over a fixed bed of cobalt catalysts, yielding a cyclohexanol-cyclohexanone mixture (KA oil). The boric acid present in the aqueous phase is crystallized, dehydrated, and recycled to the first oxidation reactor.
Purification. The organic effluent from CHHP oxidation goes through a series of purification steps. First, unreacted cyclohexane is stripped and recovered. Second, heavy ends are removed via distillation to be used as fuel, yielding the refined KA Oil product.
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the KA Oil 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 KA Oil 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 KA Oil 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 KA Oil 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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