Adipic Acid Production from Benzene (Cyclohexane Intermediate)
Adipic Acid Production Costs Report | Issue E | Q4 2024
| Report Details |
| 350 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 350 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 report presents the economics of Adipic Acid production from benzene in the United States using a two-stage oxidation process similar to Invista process. In this process, benzene is hydrogenated to cyclohexane, which is then oxidized to produce adipic acid with KA oil as intermediate.
The report provides a comprehensive study of Adipic Acid production and related Adipic Acid production cost, covering three key aspects: a complete description of the Adipic Acid production process examined; an in-depth analysis of the related Adipic Acid plant capital cost (Capex); and an evaluation of the respective Adipic Acid plant operating costs (Opex).
The Adipic Acid 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 Adipic Acid 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 Adipic Acid 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 four major sections: (1) Benzene Hydrogenation; (2) Nitric Acid Synthesis; (3) Cyclohexane Oxidation; and (4) KA Oil Oxidation.
Benzene Hydrogenation. Fresh Benzene and hydrogen are fed to a bubble column reactor, then the reactor top product is fed to a finishing fixed-bed reactor to complete benzene hydrogenation. In both steps the reaction is catalyzed by nickel based catalysts. The output from the finishing reactor is separated in a knock-out drum in two phases, a hydrogen rich gaseous phase that is recycled to the primary reactor, and a liquid stream rich in cyclohexane that is purified in a distillation column before it is directed to the Cyclohexane Oxidation section.
Nitric Acid Synthesis. Ammonia is initially oxidized to nitric oxide at medium pressure (4 - 6 bar abs) and temperatures between 870 to 930°C in the presence of platinum-rhodium catalyst gauzes. Then, nitric oxide is oxidized to form nitrogen dioxide, which is then absorbed (at the same pressure) by water, producing 65 wt% Nitric Acid.
Cyclohexane Oxidation. Cyclohexane is fed to the first of several staged air oxidation vessels, along with boric acid. In the presence of cobalt naphthenate catalysts, cyclohexane undergoes several reactions until it is finally converted into a mixture of cyclohexanol-cyclohexanone (KA oil).
KA Oil Oxidation. The KA oil is then reacted with nitric acid in the presence of copper/vanadium catalyst to form Adipic Acid. The oxidation reaction is extremely quick; it is carried out in two converters, operating at different temperatures. Most of the KA oil is oxidized in the first, low-temperature converter, with the remainder being converted in the high-temperature converter downstream. Nitrogen oxides and nitrogen are released from the reaction. After separation of water and monobasic acids from the oxidation product, crystallization under vacuum and centrifugation, a crude Adipic Acid is obtained. Finally, the crude Adipic Acid is re-dissolved in water, recrystallized, centrifuged, and dried, yielding fiber-grade Adipic Acid.
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Production Process Information
Process Consumptions
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Operating Cost Summary
Production Costs Datasheet
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Operating Cost Details
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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 Adipic Acid 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 Adipic Acid 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 Adipic Acid 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 Adipic Acid 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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This feasibility study assesses the production of Adipic Acid from benzene and propylene in the United States. In the process depicted, phenol is initially produced from benzene and propylene by means of alkylation, oxidation and cleavage. Then, phenol is hydrogenated to produce KA oil, which is then oxidized with nitric acid to produce Adipic Acid.
Details: 350 kta United States-based plant | Q4 2024 | 107 pages | Issue G From $1,499 USD
The cost analyses presented in this report target a 350 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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This report presents the economics of high-purity Adipic Acid production starting from a crude adipic acid stream from a conventional two-stage oxidation process (similar to Invista technology). The crude stream passes through a series of purification steps that include centrifugation, crystallization and drying. The process under analysis assumes a plant located in the United States.
Details: 350 kta United States-based plant | Q4 2024 | 107 pages | Issue I From $799 USD
The cost analyses presented in this report target a 350 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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