Production Cost Report | Healthcare

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DL Methionine Production Cost Breakup from Acrolein and Methyl Mercaptan

Details: Germany - based plant Q1 2024  | From $ USD

This report proffers an exhaustive cost evaluation of the production of DL-Methionine from acrolein and methyl mercaptan. This multi-step process involves reactions like mercaptan synthesis, condensation, amination, hydrolysis, and decarboxylation. In this process, firstly methyl mercaptan (methanol and hydrogen sulfide are reacted to produce methylmercaptan) is condensed with acrolein using a base catalyst. The resulting methylmercaptopropionaldehyde (MMP) undergoes hydrolysis, amination with ammonia, and decarboxylation at high temperature. The crude DL-methionine formed is purified by crystallization or ion-exchange chromatography. 

Sodium hydroxide solution is added to this and heated to give salts of dl-methionine, followed by heating the mixture, cooling the dl-methionine solution, decolorizing, and neutralizing to obtain precipitated dl-methionine, led by the addition of hydrochloric acid to completely precipitate dl-methionine followed by filtering and evaporation of hydrochloric acid to give pure dl-methionine finally.

The project economic analysis provided in the report discusses a Germany-based plant:

  • Manufacturing Process
    • Process Flow
    • Material Flow
    • Material Balance
  • Raw Material and Product's Specifications
    • Raw Material Consumption
    • Product and Co-Product Generation
    • Capital Investment
  • Land and Site Cost
    • Offsites/Civil Works
    • Equipment Cost
    • Auxiliary Equipment Cost
    • Contingency
    • Engineering and Consulting Charges
    • Working Capital
  • Variable Cost
    • Raw Material
    • Utilities
  • Fixed Cost
    • Labor Requirement & Wages
    • Overhead Expenses
    • Maintenance Charges
  • Financing Costs
    • Interest on Working Capital
    • Interest on Loans
  • Depreciation Charges
  • General Sales and Admin Costs
  • Production Cost Summary
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Report Content

Key Process Information

Evaluation of significant technical parameters along with process descriptions such as:

  • Consumption of Raw Material
  • Product Creation
  • Block Flow Diagram
  • Description of the Manufacturing Facility

Utilities Consumption

Evaluation of utilities consumed during the entire process based on:

  • Consumption per unit of product generated
  • Utility cost split and share of each utility in the total cost

Process Flow Diagram

Representation of various operations involved including:

  • Step-wise process
  • Utility consumption in each operation

Capital Cost Analysis

In-depth analysis of costs involved in setting up a new manufacturing unit, including:

  • Cost of Building a Process Unit
  • Cost of Setting Up the Infrastructure
  • Working Capital
  • Commissioning & Start-Up of the Plant

Implementation Schedule

Time frame of the project design, which includes:

  • Plant Start-Up
  • Plant Construction
  • Engineering Fundamentals
  • Raw Material Procurement

Construction Cost Details

Detailed analysis of costs involved in the operation of various functional units in the process unit and infrastructure.

Operating Cost Analysis

Evaluation of costs associated with the production of the final product, namely:

  • Procurement of Raw Materials
  • Consumption of Utilities
  • Fixed Costs
  • Depreciation

Economic Analysis

Analysis of the way in which process economics are impacted by plant capacity.

  • Construction Cost
  • Working Capital
  • Fixed and Variable Operating Costs
  • Corporate Overhead
  • Depreciation

Customized Analyses

Detailed cost estimates of any industrial plant depending on your requirements, including plant capacity and location as per the need.

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