Acetaldehyde Production from Acetylene (Liquid-Phase Hydration)
Acetaldehyde Production Costs Report | Issue C | Q4 2024
| Report Details |
| 70 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 70 kta (kilo metric ton per annum) United States-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.
Report Abstract
This study concerns Acetaldehyde production in the United States. The process reviewed in the study is an acetylene hydration in liquid phase similar to the technology developed by Chisso.
The report provides a comprehensive study of Acetaldehyde production and related Acetaldehyde production cost, covering three key aspects: a complete description of the Acetaldehyde production process examined; an in-depth analysis of the related Acetaldehyde plant capital cost (Capex); and an evaluation of the respective Acetaldehyde plant operating costs (Opex).
The Acetaldehyde 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 Acetaldehyde 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 Acetaldehyde plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Process Schematic
The process under analysis comprises two major sections: (1) Acetaldehyde synthesis; and (2) purification.
Acetaldehyde synthesis. Initially, the acetylene gas feeds a vertical reactor (hydrator), where it is hydrated with water. An aqueous solution of mercury and iron salts is used as catalyst. Unreacted acetylene and acetaldehyde entrained in the off-gases from the reactor are recovered by water scrubbing and returned to the reactor. The solution containing the Acetaldehyde formed is withdrawn from the bottom of the reactor and pumped to a flash vessel, with part of it being diverted to a catalyst regeneration step.
Purification. The solution containing the Acetaldehyde is fed to a vacuum flasher in which approximately most of the Acetaldehyde formed is flashed. The liquid stream from the flash vessel is returned to the reaction. The vapor originated in the flasher is cooled so that water and acetic acid are condensed and the solution obtained, also containing metallic mercury, is directed to a catalyst regeneration step. The resulting vapor is compressed and distilled, yielding high purity Acetaldehyde.
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Production Process Information
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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
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Acetaldehyde 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 Acetaldehyde 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 Acetaldehyde 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 Acetaldehyde 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
Other Acetaldehyde Production Cost Reports
Acetaldehyde Production from Acetic Acid
This report presents the economics of Acetaldehyde production from acetic acid in the United States using a hydrogenation process over a palladium on iron oxide catalyst.
Details: 50 kta United States-based plant | Q4 2024 | 107 pages | Issue A From $999 USD
The cost analyses presented in this report target a 50 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.
Acetaldehyde Production from Ethylene (Two-Step Process)
This report presents a techno-economic analysis of Acetaldehyde production from ethylene in the United States using a typical two-step oxidation process. In this process ethylene is oxidized by air to Acetaldehyde in tubular reactors, using a palladium/copper catalyst system.
Details: 70 kta United States-based plant | Q4 2024 | 107 pages | Issue B From $999 USD
The cost analyses presented in this report target a 70 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.
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