Commodity Production Costs Report
DL-Methionine from Methional and Hydrogen Cyanide
Methionine Operating Costs & Plant Construction Costs
This report provides the economics of DL-Methionine production from methional and hydrogen cyanide (HCN) in the United States via a typical carbonate process. Initially, methional is reacted with HCN, ammonia and carbon dioxide to produce 5-(2-methylmercaptoethyl)-hydantoin (MMEH), which is hydrolyzed to potassium methioninate (KMET). Finally, the KMET is acidified, liberating methionine.
The report provides a comprehensive study of Methionine production and related Methionine production cost, covering three key aspects: a complete description of the Methionine production process examined; an in-depth analysis of the related Methionine plant capital cost (Capex); and an evaluation of the respective Methionine plant operating costs (Opex).
The Methionine 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 Methionine 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 Methionine 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 four major sections: (1) Hydantoin Production; (2) Hydantoin Hydrolysis; (3) DLM Production and Filtration; and (4) Drying
Hydantoin production. An aqueous solution of MMP, HCN, of carbon dioxide and ammonia is fed to the hydantoin primary reactor. A gas stream containing CO2, NH3 and impurities leaves the reactor and is washed with MMP and water in a scrubbing column. Purified CO2 leaves the overheads and is used in DLM production. The mixture leaving the reactor is fed to the hydantoin secondary reactor, where the reaction is completed.
Hydantoin hydrolysis. The hydantoin product stream and potassium carbonate (K2CO3) are fed to the hydrolysis reactive column. CO2 and NH3 are liberated in the overhead stream of the column and recycled to the hydantoin primary reactor. The bottom stream containing potassium methioninate (KMET) is sent to DLM production. The K2CO3 is obtained from the regeneration of a potassium bicarbonate (KHCO3) solution from DLM filtration. This occurs in a decarbonator, where CO2 is separated in the overheads and directed to the DLM reactor.
DLM production and filtration. The KMET stream and recycled CO2 are fed to the DLM reactor, forming KHCO3 and DLM. The DLM is fed to two vacuum crystallizers. Next, DLM crystals are directed to a vacuum filter. The resulting filtrate containing KHCO3 is sent to the decarbonator.
Drying. The methionine cake is directed to a dryer. The evaporated water is fed to a wash column and reused in methionine washing during filtration. Methionine product (99 wt%) is obtained and sent to packaging and storage in warehouses.
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Methionine 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 Methionine 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 Methionine 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 Methionine 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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