Commodity Production Costs Report

Polyoxymethylene Production from Methanol and Acetic Anhydride

Polyoxymethylene Operating Costs & Plant Construction Costs

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

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.

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): ?

Polyoxymethylene Production Cost Report Process Schematic

The process under analysis comprises three major sections: (1) Partial Oxidation; (2) Formaldehyde Purification; and (3) Polymerization.

* Partial oxidation. Fresh methanol and air are fed to an evaporator, and the resulting vapor is mixed with steam and sent to a reactor, where the methanol is partially oxidized in the presence of a catalyst bed of silver crystals, yielding a formaldehyde solution and hydrogen. The hydrogen generated is also burned by the oxygen, forming water.

* Formaldehyde Purification. The reactor effluent is fed to the absorption column. Methanol and formaldehyde are absorbed and sent to the methanol stripper. This stripper separates unreacted methanol, which is recycled to the reactor, from formaldehyde, which is routed to the ion exchanger and then 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 to recover cyclohexanol. The hemiformal is sent to the pyrolysis area, where it is cracked to split off the formaldehyde monomer, which is directed to the polymerization reactor.

* Polymerization. Formaldehyde is fed to a reactor and polymerized into POM, which precipitates as it is formed. The solid particles are separated from the solvent in a vacuum filter, are dried to remove volatile materials, and routed to the acetylation reactor, where hydroxyl groups on the polymer chain are converted to acetate groups. The product from acetylation reactor is routed to a hot nitrogen dryer to remove residual acetic anhydride, which is recycled to anhydride recovery. The acetic anhydride stream is recovered, refined, and recycled to the acetylation reactor. The dried product is then sent to an extruder, to blending silos, and it is then packed and stored.

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  • Production Process Information
  • Process Consumptions
  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
  • Production Costs Datasheet
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 80 Pages | 22 Tables | 9 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
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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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  • Updated with Q3 2024 Data
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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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Polyoxymethylene from Formaldehyde and Acetic Anhydride

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.

Details: 110 kta United States-based plant | Q3 2024 | 107 pages | Issue A | From $1,999 USD

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