Commodity Production Costs Report
MDI Production from Aniline (Phosgenation Process)
Methylene Diphenyl Diisocyanate Operating Costs & Plant Construction Costs
This study presents the costs associated with the construction of a plant producing MDI from aniline and formaldehyde in the USA. In this study aniline reacts with formaldehyde to form a mixture of diphenyl methane diamine and polymeric amines. Then, this mixture reacts with phosgene to produce MDI and polymeric MDI. The phosgene used is generated from chlorine in an on-site unit.
The report provides a comprehensive study of Methylene Diphenyl Diisocyanate production and related Methylene Diphenyl Diisocyanate production cost, covering three key aspects: a complete description of the Methylene Diphenyl Diisocyanate production process examined; an in-depth analysis of the related Methylene Diphenyl Diisocyanate plant capital cost (Capex); and an evaluation of the respective Methylene Diphenyl Diisocyanate plant operating costs (Opex).
The Methylene Diphenyl Diisocyanate 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 Methylene Diphenyl Diisocyanate 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 Methylene Diphenyl Diisocyanate 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): ?
Product
MDI. MDI or Methylene Diphenyl Diisocyanate is a chemical primarily used in the production of polyurethane foams, elastomers, and coatings. It reacts with polyols to form flexible and rigid foams, essential in insulation and cushioning applications. MDI is produced via the phosgenation of methylene dianiline and is stored as a liquid. It is crucial for producing high-performance materials like adhesives and sealants, and its versatility enables its use in automotive, construction, and furniture industries.
Raw Materials
Formalin. Formaldehyde is a colorless, strong-smelling gas remarkably versatile as a chemical intermediate - it is widely used for the production of resins and coatings employed in the manufacture of building materials and household products. Since the pure gas slowly polymerizes at temperatures lower than 80°C, formaldehyde is usually available as a liquid solution in water with small amounts of methanol. This solution is called formalin. Most of world's formalin is commercially manufactured from methanol and air in the presence of a silver (or a metal oxide) catalyst.
Chlorine. Chlorine figures among the most important chemical commodities. It is an indispensable intermediate in the chemical industry, employed in the manufacture of a multitude of end products (e.g. materials of construction, solvents, pesticides, etc). Most of chlorine produced on commercial scale is based on electrolysis of aqueous sodium chloride (brine), which also generates caustic soda and hydrogen as co-products (chlor-alkali processes).
Aniline. Aniline is an important organic compound used primarily in the production of polyurethane foam, rubber processing chemicals, and dyes. Its versatility in chemical synthesis makes it a key intermediate for several industrial applications. Aniline is produced by the hydrogenation of nitrobenzene. It is stored as a liquid at room temperature and requires careful handling due to its toxicity.
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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 Methylene Diphenyl Diisocyanate 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 Methylene Diphenyl Diisocyanate 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 Methylene Diphenyl Diisocyanate 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 Methylene Diphenyl Diisocyanate 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 Methylene Diphenyl Diisocyanate Production Cost Reports
MDI Production from Aniline (Carbonylation Process)
This report presents the economics of Methylene Diphenyl Diisocyanate (MDI) production from aniline and formaldehyde using a typical oxidative carbonylation process located in the USA. In this process, aniline undergoes oxidative carbonylation to give ethyl phenylcarbamate (EPC). Then, the EPC reacts with formaldehyde to form diphenylene diurethane (MDU). Finally, MDU is thermally decomposed to MDI.
Details: 50 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $1,199 USD
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Other Related Production Cost Reports
Chlorine Production from Sodium Chloride (Diaphragm Process)
This study presents the economics of Chlorine production from sodium chloride via a diaphragm plant located in the United States. In the process under analysis, an aqueous solution of sodium chloride (brine) is decomposed electrolytically in a diaphragm cell, producing Chlorine, sodium hydroxide and hydrogen.
Details: 550 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $799 USD
Formaldehyde from Methanol (Silver Catalyst and Full Conversion)
This report presents a techno-economic study of Formalin (37wt% aqueous solution of Formaldehyde) production from methanol in the United States. The oxidation-dehydrogenation uses a silver-catalyzed reaction at conditions that prioritize full methanol conversion. In this case, methanol recovery is unnecessary.
Details: 60 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $799 USD
Aniline Production from Nitrobenzene (Vapor-Phase Hydrogenation)
This report presents the economics of Aniline production from nitrobenzene and hydrogen in the United States through a process similar to BASF's vapor phase nitrobenzene hydrogenation. In this process, nitrobenzene is reduced to Aniline.
Details: 330 kta United States-based plant | Q3 2024 | 107 pages | Issue A | From $799 USD
Polyether Thermoplastic Polyurethane from MDI and PTMEG
This study presents the economics of Polyether Themoplastic Polyurethane (TPU) production from methylene diphenyl diisocyanate (MDI) and polytetramethylene ether glycol (PTMEG) in the United States, via a typical one-shot polymerization in a twin-screw reactive extruder.
Details: 20 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $799 USD
Chlorine Production from Sodium Chloride (Membrane Process)
This study presents the economics of Chlorine production from sodium chloride via a membrane process plant located in the United States. In the process under analysis, an aqueous solution of sodium chloride (brine) is decomposed electrolytically in a membrane cell, producing Chlorine, sodium hydroxide and hydrogen.
Details: 500 kta United States-based plant | Q3 2024 | 107 pages | Issue A | From $799 USD
Formaldehyde from Methanol (Silver Catalyst and Methanol Recycle)
This report presents a techno-economic study of Formalin (37wt% aqueous solution of Formaldehyde) production from methanol in the United States by oxidation-dehydrogenation using a silver-catalyzed reaction at conditions that prioritize selectivity over conversion. In this case, unconverted methanol is recycled.
Details: 60 kta United States-based plant | Q3 2024 | 107 pages | Issue A | From $799 USD
Polyester Thermoplastic Polyurethane from MDI and Polyester Diol
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Details: 20 kta United States-based plant | Q3 2024 | 107 pages | Issue A | From $799 USD
Aniline Production from Nitrobenzene (Liquid-Phase Hydrogenation)
This report examines the costs related to the Aniline production from nitrobenzene and hydrogen in the USA. In this process, nitrobenzene is submitted to a liquid phase hydrogenation, being reduced to Aniline.
Details: 350 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $799 USD
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