Commodity Production Costs Report
DL-Methionine Production from Acrolein, Methyl Mercaptan and HCN
Methionine Operating Costs & Plant Construction Costs
This report presents the economics of DL-Methionine production from acrolein, methyl mercaptan, and hydrogen cyanide (HCN) in the United States. In this process, refined acrolein and methyl mercaptan are reacted to form MMP (also called methional), which is further reacted with HCN to generate DL-Methionine via a typical carbonate process.
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 can be divided into four main areas: (1) MMP production; (2) hydantoin production; (3) hydantoin hydrolysis; and (4) DLM production.
* MMP production. Acrolein gas is fed to an absorber, where it is contacted with a circulating liquid mixture containing mainly MMP, methyl mercaptan and catalyst/stabilizer. In the liquid phase, the acrolein reacts with methyl mercaptan generating MMP. The MMP generated exits through the bottom of the absorber, while impurities are stripped from the top of the absorber column.
* Hydantoin production. The MMP is reacted with HCN and an aqueous solution of carbon dioxide (CO2) and ammonia (NH3) to form the intermediate hydantoin (which corresponds to 5-(2-methylmercaptoethyl)hydantoin). The reaction occurs in two reactors.
* Hydantoin hydrolysis. The hydantoin product stream and potassium carbonate (K2CO3) are fed to the hydrolysis reactive column. CO2 and NH3 liberated by column's top are recycled to the hydantoin primary reactor. The bottom stream, containing potassium methioninate (KMET), is sent to the DLM production section.
* DLM production. The KMET stream and recycled CO2 are fed to the DLM reactor, forming KHCO3 and DLM. The methionine is fed to a vacuum crystallizer and the crystals are vacuum-filtered. The resulting KHCO3-containing filtrate is sent to the decarbonator for K2CO3 regeneration. The Methionine cake is dried and sent to packaging and storage.
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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 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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