Commodity Production Costs Report
Methyl Acrylate Production
Methyl Acrylate Operating Costs & Plant Construction Costs
This report presents the economics of Methyl Acrylate production from acrylic acid and methanol in the United States, via a direct esterification process similar to the Synthomer process. The esterification is conducted in a fixed bed reactor, packed with an ion-exchange resin that is used as strong acid catalyst.
The report provides a comprehensive study of Methyl Acrylate production and related Methyl Acrylate production cost, covering three key aspects: a complete description of the Methyl Acrylate production process examined; an in-depth analysis of the related Methyl Acrylate plant capital cost (Capex); and an evaluation of the respective Methyl Acrylate plant operating costs (Opex).
The Methyl Acrylate 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 Methyl Acrylate 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 Methyl Acrylate 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 examined comprises two main sections: (1) esterification, and (2) purification.
Esterification. Acrylic acid is initially reacted with methanol to produce Methyl Acrylate. Such esterification reaction is carried out in a fixed bed reactor, packed with an ion-exchange resin used as strong acid catalyst. The reactions occur in the liquid phase, and a small excess of methanol is used to improve reaction kinetics and shift the reaction toward the ester formation.
Purification. After the esterification, acrylic acid and heavy by-products formed by the reaction are separated from the esterification product and recycled. The unreacted methanol is also extracted from the crude ester, distilled, and recycled. A final distillation removes the impurities from the product, yielding 99.5% pure Methyl Acrylate.
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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 Methyl Acrylate 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 Methyl Acrylate 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 Methyl Acrylate 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 Methyl Acrylate 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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