Commodity Production Costs Report

Polyethylene Furanoate Production from FDCA

Polyethylene Furanoate Operating Costs & Plant Construction Costs

300 kta United States-based plant | 107 Pages | Issue A | Q3 2024
Starting at $1,199 USD | See Report Editions Prices

This report presents the economics of Polyethylene Furanoate (PEF) production from monoethylene glycol (MEG) and 2,5-furandicarboxylic acid (FDCA). In the process under analysis, FDCA and MEG are polymerized to PEF in two polymerization steps: melt-phase polymerization and solid-state polymerization. The economic analysis provided assumes a plant located in the United States.

The report provides a comprehensive study of Polyethylene Furanoate production and related Polyethylene Furanoate production cost, covering three key aspects: a complete description of the Polyethylene Furanoate production process examined; an in-depth analysis of the related Polyethylene Furanoate plant capital cost (Capex); and an evaluation of the respective Polyethylene Furanoate plant operating costs (Opex).

The Polyethylene Furanoate 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 Polyethylene Furanoate 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 Polyethylene Furanoate 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): ?

Polyethylene Furanoate Production Cost Report Process Schematic

The process under analysis comprises two major sections: (1) Melt-phase polymerization; and (2) Solid-state polymerization.

Melt-phase polymerization. MEG and FDCA are initially fed to the paste system which prepares, in batches, a uniform feed slurry for melt-polymerization downstream. The mixture then passes through two agitated and jacketed reactors, in which esterification takes place generating bis(2-hydroxyethyl)-2,5-furandicarboxylate (BHEF). The BHEF monomer is fed to an agitated, jacketed reactor. Here, vacuum and heat are applied for the removal of water and ethylene glycol, shifting the reaction equilibrium towards polymerization. Antimony glycolate is used as catalyst. This pre-polymerization generates PEF oligomers. In the polycondensation step, the PEF oligomers condensate, increasing the degree of polymerization. The reaction occurs at a rotating disc reactor under an even higher vacuum, removing water and excess MEG. Here, higher molecular weight PEF chains are generated, yielding a textile fiber-grade PEF. Gaseous effluents from all reactors are condensed and fed to a distillation column where MEG is recovered in the bottom and recirculated. The previous melt-phase polymerization is concluded by a Pelletizing step, in which the molten PEF is extruded, cooled, and chopped into cylindrical shapes. The amorphous PEF chips are screened, classified, dried and then conveyed to a silo.

Solid-state polymerization. The PEF chips are crystallized, to not stick together or agglomerate due to high polymerization temperatures downstream. The crystallized particles are then polycondensed in the SSP reactor, a long cylindrical hopper-type vessel. The bottle-grade PEF chips are fed to a fluidized-bed cooler, which cools down the PEF and removes dust. The PEF chips are homogenized and packed in bags.

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  • Production Process Information
  • Process Consumptions
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  • Operating Cost Summary
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 80 Pages | 22 Tables | 9 Images

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Table of Contents


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  • Production Process Information
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  • Operating Cost Summary
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  • Operating Cost Details
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 90 Pages | 28 Tables | 13 Images

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Table of Contents


Features
  • Production Process Information
  • Process Consumptions
  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
  • Production Costs Datasheet
  • Plant Capital Cost Details
  • Operating Cost Details
  • Plant Cost Breakdowns
  • Plant Capacity Assessment
  • Process Flow Diagrams
  • Costs in Different Countries Add-on
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  • 107 Pages | 34 Tables | 22 Images
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Content Highlights

Plant Capital Cost Summary

Summary outlining the capital cost required for building the Polyethylene Furanoate 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 Polyethylene Furanoate 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 Polyethylene Furanoate 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 Polyethylene Furanoate 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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Polyethylene Furanoate Production from Glucose

This report, in turn, presents the economics of Polyethylene Furanoate (PEF) production from monoethylene glycol (MEG) and glucose syrup in the United States. In this process, a glucose is isomerized to fructose. Then, fructose is converted to methoxy methyl furan (MMF) intermediate, which is oxidized to FDCA. This process is similar to Avantium YXY. FDCA generated and MEG are then polymerized to PEF in melt-phase and solid-state polymerization.

Details: 300 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $1,499 USD

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Polyethylene Furanoate Production from Raw Sugar

This report presents the economics of Polyethylene Furanoate (PEF) production from raw sugar and monoethylene glycol (MEG) similar to Avantium YXY in Germany. Initially, raw sugar is inverted to fructose and glucose, which is isomerized to fructose. Then, fructose is converted to methoxy methyl furan (MMF), which is oxidized to FDCA. FDCA generated and MEG are then polymerized to PEF in melt-phase and solid-state polymerization.

Details: 300 kta Germany-based plant | Q3 2024 | 107 pages | Issue C | From $1,499 USD

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This report presents the economics of 2,5-Furandicarboxylic Acid (FDCA) production from glucose syrup via a furan process similar to Avantium YXY technology. Initially, glucose is enzymatically isomerized into fructose, which is dehydrated in the presence of methanol, yielding methoxymethylfurfural (MMF). Finally, MMF is oxidized to FDCA. The economic analysis assumes a plant constructed in the United States.

Details: 270 kta United States-based plant | Q3 2024 | 107 pages | Issue A | From $1,199 USD

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