Methyl Methacrylate Production from Acetone, NH3 and Natural Gas
Methyl Methacrylate Production Costs Report | Issue C | Q3 2024
| Report Details |
| 120 kta United States-based plant | Q3 2024 | 107 pages |
This report presents a cost analysis of a 120 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 a process similar to Evonik Aveneer for Methyl Methacrylate (MMA) production from acetone and hydrogen cyanide (HCN) in the United States. Initially, HCN is produced from ammonia (NH3) and natural gas in an on-site unit. Then, acetone and methanol are used as raw materials for the production of MMA in six main steps, which are described in the report.
The report provides a comprehensive study of Methyl Methacrylate production and related Methyl Methacrylate production cost, covering three key aspects: a complete description of the Methyl Methacrylate production process examined; an in-depth analysis of the related Methyl Methacrylate plant capital cost (Capex); and an evaluation of the respective Methyl Methacrylate plant operating costs (Opex).
The Methyl Methacrylate 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 Methyl Methacrylate 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 Methyl Methacrylate 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) Hydrogen Cyanide (HCN) Production; (2) 2-hexyl alpha-hydroxyisobutyrate (2-EHHIB) Synthesis; and (3) Methyl Methacrylate (MMA) Production.
Hydrogen Cyanide (HCN) Production. Air, natural gas and fresh and recovered ammonia (NH3) are fed to a reactor, where HCN is produced. The reactor effluent is sent to the NH3 Absorber, which absorbs unreacted ammonia. The absorber's bottom stream is routed to an ammonia redovery section, while its overhead stream is directed to HCN recovery & purification section. Purified HCN is stored in a Surge Tank before being used downstream.
2-EHHIB Synthesis. The HCN from previous section reacts with acetone, yielding acetone cyanohydrin (ACH), which is sent to a hydrolysis reactor to form alpha-hydroxyisobutyramide (HIBA). The hydrolysis product is distilled for the removal of impurities and unreacted components (e.g. acetone) - withdrawn from the top of the column. High-purity HIBA is obtained from the bottom of the column and routed to tubular reactors where it reacts with 2-ethylhexanol (2-EH) yielding 2-EHHIB and NH3. The reactors outlet streams are sent to subsequent distillation columns for 2-EHHIB purification and unreacted components recovery, which are recycled to the reactors. Ammonia obtained from the reaction is separated from unreacted 2-EH and recycled to the HCN synthesis section.
Methyl Methacrylate (MMA) Production. The purified 2-EHHIB is fed to a transesterification section, where it is reacted with methanol to generate methyl alpha-hydroxybutyrate (MHIB) - 2-EH is also generated in this reaction and is recycled to the 2-EHHIB sythesis section. After being separated from 2-EH, the MHIB-rich stream is sent to the cross-transesterification section, where it reacts with methacrylic acid (MAA) to form Methyl Methacrylate (MMA) and ?-hydroxyisobutyric acid (HIBAc). While HIBAc is dehydrated back into MAA to be reused in the process, MMA is sent to a set of distillation columns, from which high-purity MMA product is obtained and methanol is recovered for being recycled to the transesterification section.
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Production Process Information
Process Consumptions
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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 Methyl Methacrylate 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 Methyl Methacrylate 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 Methyl Methacrylate 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 Methyl Methacrylate 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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