Commodity Production Costs Report
Nitrobenzene Production from Benzene (KBR)
Nitrobenzene Operating Costs & Plant Construction Costs
This report presents the economics of Nitrobenzene production from benzene and nitric acid in the United States. The process examined in this report is similar to KBR's (formerly Chematur) process, in which a tubular reactor is used.
The report provides a comprehensive study of Nitrobenzene production and related Nitrobenzene production cost, covering three key aspects: a complete description of the Nitrobenzene production process examined; an in-depth analysis of the related Nitrobenzene plant capital cost (Capex); and an evaluation of the respective Nitrobenzene plant operating costs (Opex).
The Nitrobenzene 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 Nitrobenzene 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 Nitrobenzene 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 three major sections: (1) Benzene Nitration; (2) Washing; and (3) Purification.
Benzene Nitration. Benzene is preheated and fed the tubular nitration reactor. Nitric acid (65 wt% solution in water) is also preheated and mixed with fresh and recycled (re-concentrated) sulfuric acid before being fed into the reactor. In the nitration, benzene reacts with nitric acid producing Nitrobenzene. The process operates with a stoichiometric excess of benzene to ensure that complete nitric acid conversion is obtained in the nitration. The reaction product is sent to a decanter, where crude Nitrobenzene is separated from the spent sulfuric acid. Spent sulfuric acid recovered from separator is re-concentrated and recycled to the nitration reactor.
Washing. This section comprises three wash steps for removal of nitrophenols, dinitrobenzene, and the acid entrained with the crude Nitrobenzene. In the first wash step, the acidic wash, the crude Nitrobenzene is contacted with recovered process water to remove mineral acids, mainly sulfuric and nitric acids. In the second wash step, the alkaline wash, the organic by-products formed in the nitration (e.g.: nitrophenols) are extracted from the crude Nitrobenzene stream by washing with a sodium hydroxide solution. In the third wash, the neutral wash, small amounts of sodium hydroxide and salt (sodium-nitrophenolates) from the alkaline wash, are removed by washing with process water.
Purification. The product leaving the washing system is sent to a steam stripper to recover the excess benzene, which remains in solution with the Nitrobenzene up to this point in the process. Benzene stream is separated from water and recycled. The bottom of the stripping column, comprising Nitrobenzene product is sent to the Nitrobenzene surge tank, located outside battery limits, before being sent to the final consumer.
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Nitrobenzene 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 Nitrobenzene 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 Nitrobenzene 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 Nitrobenzene 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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Nitrobenzene Production from Benzene (NORAM)
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