Acrylic Acid and Acrylates
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1 Acrylic Acid and Acrylates Table of Contents A Report by NexantThinking Process Evaluation/Research Planning (PERP) Program PERP Report PERP Published September 2014 Section Page 1 Executive Summary OVERVIEW COMMERCIAL TECHNOLOGIES ALTERNATIVE TECHNOLOGIES PROCESS ECONOMICS Acrylic Acid Acrylate Esters COMMERCIAL APPLICATIONS REGIONAL MARKET ANALYSIS Acrylic Acid Supply/Demand Acrylates Supply/Demand Introduction OVERVIEW ACRYLIC ACID Acrylic Acid Technology Business Developments Technology Holders and Licensing Status Strategic and Business Considerations Physical Properties and Specifications Health Hazards Storage and Transportation ACRYLATE ESTERS Acrylate Ester Technology Business Developments Strategic and Business Considerations
2 2.3.4 Physical Properties and Specifications Health Hazards Storage and Transportation Commercial Technologies ACRYLIC ACID Acrylic Acid via Two-step Propylene Oxidation GLACIAL ACRYLIC ACID Crystallization Distillation ACRYLATE ESTERS Commodity Acrylates via Esterification Specialty Acrylates via Trans-Esterification Environmental Considerations PROCESS IMPROVEMENTS AND ON-GOING RESEARCH Arkema BASF Celanese Dow Chemicals (now Arkema) LG Chemicals Lurgi Mitsubishi Chemical Corporation Nippon Kayaku Nippon Shokubai Rohm and Haas (Dow/Arkema) Shanghai Huayi Group Sumitomo Chemical Tosoh Corporation Union Carbide Alternative Technologies BIO-BASED ACRYLIC ACID TECHNOLOGIES Acrylic Acid via 3-Hydroxypropionic Acid (3-HP) from Glucose Acrylic Acid via Acrolein from Glycerol Acrylic Acid via Fumaric Acid from Glycerol Acrylic Acid via Bio-Based Lactic Acid Acrylic Acid via Bio-Based Acetic Acid and Formaldehyde
3 4.2 BIO-ADAPTABLE ACRYLIC ACID TECHNOLOGY Acrylic Acid via Polypropiolactone from Ethylene Oxide HISTORICAL ACRYLIC ACID PROCESSES Acrylic Acid via Ethylene Acrylic Acid via Acetylene Acrylic Acid via β-propiolactone Acrylic Acid via Propylene ALTERNATIVE ACRYLATE ESTER TECHNOLOGIES Acrylic Esters via Acetylene Acrylic Esters via Acrylonitrile Acrylic Esters via Ketene Process Economics COSTING BASIS Investment Basis Pricing Basis Cost of Production Basis PROCESS BENCHMARKING Acrylic Acid Cost Comparison for the Production Acrylic Acid Acrylate Esters Sensitivity Analysis Regional Cost of Production Analysis (Cost Competitiveness) Commercial Applications CRUDE ACRYLIC ACID AND ACRYLATE ESTERS Commodity Acrylates Specialty Acrylates GLACIAL ACRYLIC ACID Polyacrylic Acid Superabsorbent Polymers Detergent Applications Miscellaneous Regional Market Analysis ACRYLIC ACID Global Overview North America
4 7.1.3 Western Europe Asia Pacific ACRYLATES Global Overview North America Western Europe Asia Pacific Rest of the World Glossary References Appendix Page A Cost of Production Estimates... A-1 B Definitions of Capital Cost Terms Used in Process Economics... B-1 C Definitions of Operating Cost Terms Used in Process Economics... C-1 D PERP Program Title Index ( )... D-1 Figure Page 1.1 Acrylic Acid Consumption Glacial Acrylic Acid Regional Cost Competitiveness Estimates n-butyl Acrylate Regional Cost Competitiveness Estimates Global Acrylic Acid End-Uses Global Breakdown of Acrylic Acid Consumption Global Acrylates End-Uses Global Breakdown of Acrylates Consumption Acrylic Acid and its Derivatives Acrylic Acid Consumption Petrochemical-based Routes to Acrylic Acid Acrylate Ester Value Chain Commodity versus Specialty Acrylates End-Uses Propylene to Acrolein Reaction Mechanism (Simplified) Primary and Secondary Oxidation with Tandem Reactors Water Quench Separation Train
5 3.4 Alternative Quench Separation Solvent Quench Separation Train Oxidation Reactor Schematic Incinerator Design (Simplified) Wastewater Treatment System (Simplified Design) BASF Process for Production and Purification of Acrylic Acid Methyl Acrylate Production Feedstock Options for BASF Production of Bio-Based Acrylic Acid Acrylic Acid via Polypropiolactone (Novomer) BASF High Pressure Reppe Process Simplified Flow Diagram for the Process Technology Benchmarking for Crude Acrylic Acid Cost Component Breakdown for Crude Acrylic Acid Technology Process Technology Benchmarking for Glacial Acrylic Acid Cost Component Breakdown for Glacial Acrylic Acid Technology Sensitivity of Acrylic Acid Production to Raw Material Pricing Sensitivity of Acrylic Acid Production to Capital Costs Glacial Acrylic Acid Regional Cost Competitiveness Estimates Estimated Regional Cost Component Summary for Glacial Acrylic Acid n-butyl Acrylate Regional Cost Competitiveness Estimates Estimated Regional Cost Component Summary for Glacial Acrylic Acid End-use Applications for Commodity Acrylates End-use Applications for Specialty Acrylates Global Acrylic Acid End-Uses Global Breakdown of Acrylic Acid Consumption Global Acrylic Acid Capacity by Region Global Acrylic Acid Supply and Demand North America Acrylic Acid End-Uses North America Acrylic Acid Supply and Demand Western Europe Acrylic Acid End-Uses Western Europe Acrylic Acid Supply and Demand Asia Pacific Acrylic Acid End-Uses Asia Pacific Acrylic Acid Supply and Demand Global Acrylates End-Uses Global Breakdown of Acrylates Consumption
6 7.13 Global Acrylates Capacity by Region Global Acrylates Supply and Demand Global Methyl Acrylate Supply and Demand Global Ethyl Acrylate Supply and Demand Global Butyl Acrylate Supply and Demand Global 2-Ethylhexyl Acrylate Supply and Demand North America Acrylates Supply and Demand Western Europe Acrylates Supply and Demand Asia Pacific Acrylates Supply and Demand ROW Acrylates Supply and Demand Table Page 1.1 Global Acrylic Acid Supply and Demand Global Acrylates Supply and Demand Licensors and Technology Holders for Acrylic Acid Key Physical and Thermodynamic Properties of Glacial Acrylic Acid Typical Commercial Specifications for Glacial Acrylic Acid Key Physical and Thermodynamic Properties of Methyl Acrylate (MA) Key Physical and Thermodynamic Properties of Ethyl Acrylate (EA) Key Physical and Thermodynamic Properties of Butyl Acrylate (nba) Key Physical and Thermodynamic Properties of 2-Ethylhexyl Acrylate (2-EHA) Typical Commercial Specifications for Commodity Acrylates NFPA Ratings for the Commodity Acrylate Esters Prices of Raw Materials, Products, Utilities, and Labor Crude Acrylic Acid via Two-Step Propylene Oxidation Glacial Acrylic Acid via Additive Enhanced Distillation of Crude Acrylic Acid (from Propylene) Glacial Acrylic Acid via Dynamic/Static Crystallization of Crude Acrylic Acid (from Propylene) Glacial Acrylic Acid via Polypropiolactone from Ethylene Oxide (petchem-based) Glacial Acrylic Acid via Polypropiolactone from Ethylene Oxide (bio-based) n-butyl Acrylate via Esterification of Crude Acrylic Acid (from Propylene) Plants Considered for Cost Competitiveness Analysis Cost of Production Estimate: Crude Acrylic Acid via Two-Step Propylene Oxidation (WE) Cost of Production Estimate: Glacial Acrylic Acid via Propylene (WE)
7 5.17 Cost of Production Estimate: Crude Acrylic Acid via Two-Step Propylene Oxidation (Japan) Cost of Production Estimate: Glacial Acrylic Acid via Propylene (Japan) Cost of Production Estimate: Crude Acrylic Acid via Two-Step Propylene Oxidation (China) Cost of Production Estimate: Glacial Acrylic Acid via Propylene (China) Estimated Regional Cost Summary for Glacial Acrylic Acid Plants Considered for Cost Competitiveness Analysis Cost of Production Estimate: n-butyl Acrylate via Esterification (WE) Cost of Production Estimate: n-butyl Acrylate via Esterification (JP) Cost of Production Estimate: n-butyl Acrylate via Esterification (CH) Global Acrylic Acid Consumption by Region Global Acrylic Acid Supply and Demand North America Acrylic Acid Capacity North America Acrylic Acid Supply and Demand Western Europe Acrylic Acid Capacity Western Europe Acrylic Acid Supply and Demand Asia Pacific Acrylic Acid Capacity Asia Pacific Acrylic Acid Supply and Demand Global Acrylates Consumption by Region Global Acrylates Supply and Demand Global Methyl Acrylate Supply and Demand Global Ethyl Acrylate Supply and Demand Global Butyl Acrylate Supply and Demand Global 2-Ethylhexyl Acrylate Supply and Demand North America Acrylate Capacity North America Acrylates Supply and Demand Western Europe Acrylates Capacity Western Europe Acrylates Supply and Demand Asia Pacific Acrylates Capacity Asia Pacific Acrylates Supply and Demand ROW Acrylates Capacity ROW Acrylates Supply and Demand
8 Nexant Thinking The NexantThinking Process Evaluation/Research Planning (PERP) program is recognized globally as the industry standard source for information relevant to the chemical process and refining industries. PERP reports are available as a subscription program or on a single report basis. Contact Details: New York: Marcos Nogueira Cesar, Vice President, Global Products, E&CA: Nexant Thinking Phone: , mcesar@nexant.com New York: Heidi Junker Coleman, Global Programs Support Manager Phone: , hcoleman@nexant.com Nexant, Inc. ( is a leading management consultancy to the global energy, chemical, and related industries. For over 38 years, Nexant has helped clients increase business value through assistance in all aspects of business strategy, including business intelligence, project feasibility and implementation, operational improvement, portfolio planning, and growth through M&A activities. Nexant has its main offices in San Francisco (California), White Plains (New York), and London (UK), and satellite offices worldwide. Copyright by Nexant Inc All Rights Reserved. 8
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