Butanediol Production from Propylene Oxide
Butanediol Production Costs Report | Issue G | Q3 2024
| Report Details |
| 100 kta United States-based plant | Q3 2024 | 107 pages |
This report presents a cost analysis of a 100 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 shows a techno-economic analysis related to the construction of a plant in the United States for 1,4-Butanediol (BDO) production from propylene oxide using a process similar to LyondellBasell. Initially, propylene oxide is isomerized to allyl alcohol. The allyl alcohol then reacts with syngas, generating 4-hydroxybutyraldehyde, which is finally hydrogenated to BDO.
The report provides a comprehensive study of Butanediol production and related Butanediol production cost, covering three key aspects: a complete description of the Butanediol production process examined; an in-depth analysis of the related Butanediol plant capital cost (Capex); and an evaluation of the respective Butanediol plant operating costs (Opex).
The Butanediol 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 Butanediol 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 Butanediol 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 three major sections: (1) Isomerization; (2) Butanediol synthesis; and (3) Purification.
Isomerization. Fresh and recycled propylene oxide streams are mixed, vaporized and superheated before being fed to the isomerization reactor. The isomerization reaction is conducted in the gas phase in a fixed-bed reactor. The reaction is promoted by a basic lithium phosphate catalyst, supported on high-purity silica. Allyl alcohol and several by-products are formed during the isomerization reaction. The isomerization effluent is then sent to two distillation columns, where unconverted propylene oxide is recovered and recycled, and the allyl alcohol is separated from the other contaminants.
Butanediol synthesis. The allyl alcohol is reacted with synthesis gas in a hydroformylation reaction, promoted by a catalyst system composed of a rhodium complex and a diphosphine. The reaction is conducted in two steps, first in a stirred tank reactor, then in a bubble column. The 4-hydroxybutyraldehyde product is recovered from the reaction medium by water extraction and it is directed to the next reaction step. The organic-phase with the catalyst system is recycled to the hydroformylation reaction. The aqueous effluent, containing the 4-hydroxybutyraldehyde is directed to a hydrogenation reactor, where the 4-hydroxybutyraldehyde reacts with hydrogen, yielding 1,4-Butanediol. This reaction is carried out in a vertical shell and tube reactor filled with a Raney nickel catalyst.
Purification. The output stream from the hydrogenation is fed to a stirred tank, where it is mixed with a sodium hydroxide solution to precipitate the dissolved nickel catalyst, which is removed by filtration. Then, propanol and water are separated in a low-boiling distillation column followed by a triple effect evaporator. n-propanol is further recovered to be sold as by-product. Finally, the concentrated stream from evaporators is directed to three distillation columns in series, where high-purity 1,4-Butanediol product is obtained as final product and 2-methyl-1,3-propanediol is obtained as by-product.
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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 Butanediol 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 Butanediol 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 Butanediol 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 Butanediol 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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