Hexamethylene Diisocyanate from HMDA (Phosgenation Process)
HDI Production Costs Report | Issue A | Q3 2024
| Report Details |
| 20 kta United States-based plant | Q3 2024 | 107 pages |
This report presents a cost analysis of a 20 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 provides the economics of a phosgenation process for Hexamethylene Diisocyanate (HDI) production from hexamethylene diamine (HMDA) in the United States. In this process, HMDA reacts with phosgene to produce HDI. The phosgene used is generated from chlorine and carbon monoxide in an on-site unit. Hydrogen chloride (HCl) is generated as by-product.
The report provides a comprehensive study of HDI production and related HDI production cost, covering three key aspects: a complete description of the HDI production process examined; an in-depth analysis of the related HDI plant capital cost (Capex); and an evaluation of the respective HDI plant operating costs (Opex).
The HDI 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 HDI 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 HDI 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) Phosgene Generation; (2) HMDA Phosgenation and (3) Purification.
Phosgene Generation. Carbon monoxide and chlorine gas are mixed and fed to a vertical shell and tube reactor, where such components react generating phosgene. The reactor is filled with activated carbon, which serve as catalyst. The effluent from the reactors is forwarded to the phosgenation section.
HMDA Phosgenation. Phosgene from the phosgene generation and phosgene recovered downstream are fed to an absorber. In the absorber the phosgene content in the gaseous feed stream is absorbed in cold ortho-dichlorobenzene (ODCB). Part of the overhead from the absorber, mostly containing HCl by-product is fed to a jacketed agitated vessel along with hexamethylenediamine (HMDA). In this reactor, the HMDA and the HCl react forming an HMDA.HCl slurry in ODCB. Such slurry is then subjected to a phosgenation reaction, carried out in a continuous two-step tank-shaped reactor. The remaining part of the overhead from the absorber is fed to a HCl recovery system, where a 32 wt% hydrochloric acid stream is obtained as by-product.
Purification. The product stream from the phosgenation reactors is initially stripped against nitrogen, for the removal of remaining phosgene and HCl content. The product stream is then passed through a solvent recovery step, so that most of the ODCB is separated and recycled. The stream rich in HDI is then passed through a series of distillation columns for the removal of heavy impurities, yielding high-purity HDI.
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Production Process Information
Process Consumptions
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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 HDI 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 HDI 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 HDI 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 HDI 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 HDI Production Cost Reports
Hexamethylene Diisocyanate from HMDA (Non-Phosgene Process)
This report presents a techno-economic analysis of Hexamethylene Diisocyanate (HDI) production from hexamethylene diamine (HMDA) in the United States. The process presented in this report is a non-phosgene process similar to BASF process. Initially, HMDA reacts with urea and butanol generating a carbamate intermediate. Then, the carbamate is thermally cracked producing HDI.
Details: 20 kta United States-based plant | Q3 2024 | 107 pages | Issue B From $799 USD
The cost analyses presented in this report target a 20 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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