Commodity Production Costs Report
Polyoxymethylene from Formaldehyde and Acetic Anhydride
Polyoxymethylene Operating Costs & Plant Construction Costs
In this report, it is assessed the production of Polyoxymethylene (POM), also called Polyacetal Resin. The economic analysis concerns Polyoxymethylene production from acetic anhydride and formaldehyde in the United States, assuming a process similar to the one owned by Dupont. Formaldehyde is initially concentrated and then polymerized in an inert cyclohexane medium. To enhance thermal stability, hydroxyl end groups are reacted with acetic anhydride.
The report provides a comprehensive study of Polyoxymethylene production and related Polyoxymethylene production cost, covering three key aspects: a complete description of the Polyoxymethylene production process examined; an in-depth analysis of the related Polyoxymethylene plant capital cost (Capex); and an evaluation of the respective Polyoxymethylene plant operating costs (Opex).
The Polyoxymethylene 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 Polyoxymethylene 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 Polyoxymethylene 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 two major sections: (1) Formaldehyde Purification; and (2) Polymerization.
Formaldehyde Purification. The formaldehyde solution is fed to a concentration column. The concentrated formaldehyde is sent to the Extraction Column, forming hemiformal by contact with cyclohexanol. A cyclohexanol-water mixture is routed to a decanter in order to recover cyclohexanol. The hemiformal is cracked through pyrolysis into the formaldehyde monomer, which is directed to the Polymerization Reactor.
Polymerization. In the presence of a solvent, formaldehyde is polymerized into POM, which precipitates as it is formed. The solid particles are separated from the solvent, dried to remove volatile materials. The separated solvent is filtered and retuned to the Polymerization Reactor, while solids are routed to the Acetylation Reactor, which is also fed with acetic anhydride. An acetic anhydride stream is recovered, refined, and routed to the Acetylation Reactor, where hydroxyl groups on the polymer chain are converted to acetate groups. The product is routed to a Dryer to remove residual acetic anhydride, which is recycled to acetylation reaction area. The dried product is sent to an extruder, and then homogenized, packed and stored.
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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 Polyoxymethylene 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 Polyoxymethylene 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 Polyoxymethylene 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 Polyoxymethylene 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 Polyoxymethylene Production Cost Reports
Polyoxymethylene Production from Methanol and Acetic Anhydride
This report approaches the production of Polyoxymethylene (POM) from methanol and acetic anhydride in the United States. Initially, methanol undergoes partial oxidation yielding formaldehyde over a silver catalyst. Formaldehyde is then polymerized to POM in an inert cyclohexane medium. To enhance thermal stability, hydroxyl end groups are reacted with acetic anhydride.
Details: 85 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $1,199 USD
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Formaldehyde from Methanol (Silver Catalyst and Full Conversion)
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Acetic Anhydride Production from Acetic Acid and Acetone
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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.
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