Commodity Production Costs Report
Methional Production from Propylene and Methyl Mercaptan
Methional Plant Capital & Operating Cost Analysis | United States | Q1 2026
This report presents the economics of Methional production from propylene and methyl mercaptan. In the process examined, acrolein is first produced via propylene oxidation. Methional is produced by the reaction of acrolein with methyl mercaptan.
The report provides a comprehensive study of Methional production and related Methional production cost, covering three key aspects: a complete description of the Methional production process examined; an in-depth analysis of the related Methional plant capital cost (Capex); and an evaluation of the respective Methional plant operating costs (Opex).
The Methional 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 Methional 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 Methional plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Product
Methional. Methional, also known as 3-(methylthio)propionaldehyde, 3-(methylmercapto)propionaldehyde, or MMP is a colorless liquid with an unpleasant odor and irritating vapors. It can be used in the food and beverages industries and contains both aldehyde and thioether functional groups (its chemical formula is C4H8OS). MMP is industrially produced by reacting acrolein (that can be provided by a propylene oxidation unit) and methyl mercaptan in a continuous gas-liquid reactor using an organic base as catalyst. Usually, such MMP industrial plants are integrated to methionine units.
Raw Materials
Propylene. Propylene, the main raw material consumed, is a colorless gas at room temperature. It is a low-boiling, flammable, and highly volatile gas, with molecular formula C3H6. Propylene reacts vigorously with oxidizing materials. It may be mildly irritating to the nose, throat, and respiratory tract; propylene has low acute toxicity from inhalation. PG Propylene has been mainly produced as ethylene manufacturing co-product (via steam cracking of paraffinic hydrocarbons) and by-product of petroleum refining (separation from refinery gas). Most recently, amid a tight propylene market, new and novel lower-cost chemical processes for on-purpose propylene production have emerged.
Methyl Mercaptan. Methyl mercaptan, also known as methanethiol, is a simple molecule with chemical formula CH4S. It is a colorless and flammable gas with unpleasant odor. It is irritant when in contact with the eyes, skin, and upper respiratory tract. Commercial production of methyl mercaptan is based on the reaction of methanol with hydrogen sulfide over a solid catalyst. The main use of methyl mercaptan is in the synthesis of methionine. It also serves as precursor for pesticides.
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Methional 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 Methional 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 Methional 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 Methional 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 Methional Production Cost Reports
Methional Production from Acrolein and Methyl Mercaptan
This report presents the economics of Methional production from acrolein and methyl mercaptan in the United States, via a typical reaction in the presence of triethanolamine.
Details: 40 kta United States-based plant | Q1 2026 | 107 pages | Issue A | From
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Other Related Production Cost Reports
Propylene Production from Propane (Moving-Bed Reactor)
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Methionine Hydroxy Analog Production from Methional and HCN
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