Commodity Production Costs Report
Nylon 6 Production from Caprolactam (Continuous Process)
Nylon Operating Costs & Plant Construction Costs
This report presents the economics of Nylon 6 production from caprolactam in the United States. The process examined is a typical continuous ring-opening polymerization of caprolactam via the hydrolytic mechanism, carried out in two stages, similar to technologies developed/licensed by Thyssenkrupp (Uhde Inventa-Fischer) and Air Liquide (Lurgi Zimmer). An aminoacid is the intermediate for condensation.
The report provides a comprehensive study of Nylon production and related Nylon production cost, covering three key aspects: a complete description of the Nylon production process examined; an in-depth analysis of the related Nylon plant capital cost (Capex); and an evaluation of the respective Nylon plant operating costs (Opex).
The Nylon 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 Nylon 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 Nylon 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) Polymerization; (2) Monomer Recovery; and (3) Finishing.
Polymerization. Initially, caprolactam flakes from storage facilities are passed through a crusher, in order to crush lumps formed due to storage. The crushed caprolactam falls into a steam jacketed tank, where it is melted, and subsequently pumped to a mixing tank, along with catalysts, additives and the caprolactam recycle. From the mixing tank, a homogenized feed stream is heated and sent to reaction. The polymerization is carried out continuously in pre-polymerizer, operated at higher pressures, and in a long, vertical, tubular reactor (the so-called VK tube), operated at lower pressures (slight vacuum). Water is used to initiate the caprolactam polymerization. In the pre-polymerizer, a water-rich reaction media accelerates hydrolysis and the initial coupling of the monomers. The polymer itself is formed in the VK tube, in which the polycondensation reaction approaches equilibrium in a low water environment.
Monomer Recovery. The monomers solution recovered from several process steps is concentrated and recycled to the process, while the evaporated water is condensed and routed to the water extraction unit downstream.
Finishing. The polymer melt from the reactor is cut into chips. Subsequently, the chips are passed through a water extraction unit for the removal of residual monomers and cyclic oligomers. Finally, the Nylon 6 chips are obtained after a drying step.
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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 Nylon 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 Nylon 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 Nylon 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 Nylon 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 Nylon Production Cost Reports
Nylon 6 Production from Caprolactam (Batch Process)
This report presents the economics of Nylon 6 production from caprolactam. The typical process analyzed consists of a batch ring-opening polymerization of caprolactam via the hydrolytic mechanism. The economic assessment assumes a plant located in the United States.
Details: 65 kta United States-based plant | Q3 2024 | 107 pages | Issue A | From $799 USD
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This report presents the economics of Caprolactam production from cyclohexane located in the United States. Initially, cyclohexane is oxidized to a cyclohexanol/cyclohexanone. Then, the cyclohexanol is hydrogenated to cyclohexanone, which is submitted to an oximation reaction with hydroxylamine. Finally, the cyclohexanone oxime produced is converted to Caprolactam by Beckmann rearrangement.
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