Commodity Production Costs Report
Toluene Diisocyanate Production from DNT, CO and Methanol
Toluene Diisocyanate Operating Costs & Plant Construction Costs
This report presents the economics of Toluene Diisocyanate (TDI) production from dinitrotoluene (DNT) in the United States. The process examined is a typical reductive carbonylation. DNT initially is reacted with carbon monoxide and methanol to form toluene dimethylcarbamate, which is then thermally decomposed to produce TDI.
The report provides a comprehensive study of Toluene Diisocyanate production and related Toluene Diisocyanate production cost, covering three key aspects: a complete description of the Toluene Diisocyanate production process examined; an in-depth analysis of the related Toluene Diisocyanate plant capital cost (Capex); and an evaluation of the respective Toluene Diisocyanate plant operating costs (Opex).
The Toluene Diisocyanate 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 Toluene Diisocyanate 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 Toluene Diisocyanate 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): ?
Product
TDI. TDI (Toluene Diisocyanate) is a critical raw material for producing flexible polyurethane foams, which are used in furniture, mattresses, and automotive seating. It is also used in coatings and adhesives. TDI is produced through the nitration of toluene followed by phosgenation. It is stored as a liquid and is highly reactive, requiring careful handling due to its toxicity and sensitivity to moisture.
Raw Materials
Dinitrotoluene. Dinitrotoluene is an intermediate chemical used in the production of toluene diisocyanate (TDI) and explosives. It is a key component in polyurethane foam production and in making dyes and plasticizers. Dinitrotoluene is produced by nitrating toluene with nitric acid and sulfuric acid, and it is stored as a yellow crystalline solid. Its application in both the explosive and polyurethane industries illustrates its diverse industrial significance.
Methanol. Methanol is a simple alcohol used as a solvent, antifreeze, and a feedstock for producing formaldehyde, acetic acid, and methyl tert-butyl ether (MTBE). It is also an alternative fuel in various energy applications. Methanol is produced from synthesis gas and is stored as a liquid. In addition to its widespread use in chemicals and fuels, methanol is increasingly used in the production of biodiesel and fuel cells, highlighting its role in renewable energy technologies.
Carbon Monoxide. Like hydrogen, carbon monoxide is produced industrially from syngas, but it is recovered via cryogenic distillation. Carbon monoxide is used in the chemical industries for the synthesis of several compounds, like acetic acid, polycarbonates, polyketones; and also in the metallurgical industry for the creation of reducing atmospheres.
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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 Toluene Diisocyanate 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 Toluene Diisocyanate 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 Toluene Diisocyanate 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 Toluene Diisocyanate 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 Toluene Diisocyanate Production Cost Reports
Toluene Diisocyanate from Toluene (Gas-Phase Phosgenation)
This report presents the economics of TDI production from toluene and chlorine via a process similar to the Bayer Gas-Phase Phosgenation (GPP) technology in the United States. Initially, toluene is dinitrated to dinitrotoluene (DNT). Then, DNT is hydrogenated to toluenediamine (TDA). Finally, TDA reacts with phosgene in gas phase to produce TDI. The phosgene used is generated from chlorine in an on-site unit.
Details: 300 kta United States-based plant | Q3 2024 | 107 pages | Issue F | From $1,499 USD
Toluene Diisocyanate Production from DNT and Phosgene
This study reviews the costs associated with Toluene Diisocyanate (TDI) production from dinitrotoluene (DNT) and phosgene in the United States. Initially, DNT is hydrogenated to toluenediamine (TDA). Then, TDA reacts with phosgene in liquid phase to produce TDI.
Details: 180 kta United States-based plant | Q3 2024 | 107 pages | Issue A | From $1,199 USD
Toluene Diisocyanate from DNT and Cl2 (Liquid-Phase Phosgenation)
This study presents the costs associated with Toluene Diisocyanate (TDI) production from dinitrotoluene (DNT) and chlorine in the United States. Initially, DNT is hydrogenated to toluenediamine (TDA), which is reacted with phosgene in liquid phase to produce TDI. The phosgene used in this process is generated from chlorine and carbon monoxide in an on-site unit.
Details: 180 kta United States-based plant | Q3 2024 | 107 pages | Issue C | From $1,199 USD
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Other Related Production Cost Reports
Polyether Polyurethane from TDI and Polyether Triol (Typical Foaming)
This report examines the costs related to Flexible Slabstock Polyether Polyurethane production from toluene diisocyanate (TDI) and a polyether triol in the United States, via a typical foaming process.
Details: 13 kta United States-based plant | Q3 2024 | 107 pages | Issue C | From $799 USD
Methanol Production from Naphtha
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Dinitrotoluene Production
This feasibility study provides an economic analysis of Dinitrotoluene (DNT) production from toluene and nitric acid in the United States via a two-step nitration process. Initially, nitric and sulfuric acids are reacted with toluene to form mononitrotoluene, which is further nitrated to produce DNT.
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