Cyclohexenone Production Cost Reports

The report provides detailed analysis essential for establishing a cyclohexenone production plant. It encompasses all critical aspects necessary for cyclohexenone production, including the cost of cyclohexenone production, cyclohexenone plant cost, cyclohexenone production costs, and the overall cyclohexenone production plant cost. Additionally, the study covers specific expenditures associated with setting up and operating a cyclohexenone production plant. These encompass production processes, raw material requirements, utility requirements, infrastructure needs, machinery and technology requirements, manpower requirements, packaging requirements, transportation requirements, and more.

Cyclohexenone Market Analysis: Demand and Supply Analysis and Sourcing

Cyclohexenone, also known as 2-cyclohexen-1-one, is a chemical compound with a six-membered ring containing a double bond and a ketone group. Its chemical structure makes it useful in different chemical reactions. It is mainly used to produce more complex chemicals by adding new groups or forming new molecular structures. Cyclohexenone is a specialty chemical rather than a bulk chemical and is usually sold in drums, intermediate bulk containers (IBCs), or small bottles. Production volumes are relatively low, while prices per kilogram are generally high. Buyers mainly focus on product purity, quality, and safe delivery.

Demand for cyclohexenone mainly comes from the pharmaceutical, agricultural chemical, fragrance, and research industries. Pharmaceutical companies use it to produce drug intermediates, while agricultural chemical manufacturers use it in the production of fungicides and other crop protection chemicals. Research laboratories use it to study chemical reactions and biological processes. It is also used to make other chemicals, such as substituted cyclohexanones, cyclohexenols, and bicyclic ketones. Smaller applications include insect pheromones, flavors, fragrances, and materials research. Most orders range from a few grams to several tonnes, with regular demand coming from a limited number of industrial customers.

Supply is fragmented, specialized, and heavy on trading. ChemicalBook lists about 77 Chinese suppliers, 47 in the US, 30 in India, and smaller numbers in the UK, Germany, and Japan. Most are traders, repackers, catalog firms, or custom synthesis shops rather than producers. Older EPA records reported to the NTP named Heico Chemicals as the only US maker, with volumes under 1,000 pounds, and noted that imports supply much of the market. Catalog houses such as TCI, Sigma-Aldrich, and Thermo Fisher Scientific sell research quantities. A cyclohexenone demand and supply analysis has to weigh a few real producers, many traders, strict transport rules, and the cost of cyclohexene feed.

Summary of the Product, Grades, and Uses

Cyclohexenone has the chemical formula C6H8O, a molecular weight of 96.13 g/mol, and a CAS number of 930-68-7. It is a clear liquid that is colorless when pure but can turn yellow or orange during storage. It has a boiling point of about 170 degree Celsius, a melting point of about -53 degree Celsius, and a density of around 0.99 g/cm³ at 20 degree Celsius. It has moderate solubility in water, about 41 g/L at 25 degree Celsius, and mixes easily with most organic solvents, including alcohols, ethers, and ketones. Cyclohexenone is flammable and has a flash point of about 56 degree Celsius. It has a strong smell, but the odor should not be used to judge whether exposure is safe. Light, air, and heat can cause it to darken and form unwanted impurities, which can reduce its quality. To maintain stability and safety, cyclohexenone should be stored in a cool, dark place, often below 15 degree Celsius.

Cyclohexenone is available in three main grades, based on purity and end use. Technical or synthesis grade usually has 97% to 98% purity and is mainly used by fine chemical and agrochemical manufacturers. It is generally supplied in drums or intermediate bulk containers (IBCs). High-purity grade has 98% or higher purity and very low levels of water and other impurities. It is mainly used by pharmaceutical companies to make drug intermediates. Research grade is supplied in small bottles, usually from 25 mL to 500 mL, and is used by universities, research institutions, contract research organizations (CROs), and industrial laboratories.

Each lot is tested for GC purity, water by Karl Fischer, color, acidity, and density. Key impurities include cyclohexanone, 2-cyclohexen-1-ol, cyclohexene oxide, 1,2-cyclohexanediol, and residual cyclohexene. Pharmaceutical buyers also ask for residual solvents, vanadium, cobalt, iron, and other metals from the catalyst. Buyers also check for gums and dimers after long storage. Peroxide content matters, since cyclohexenyl hydroperoxide forms in the oxidation step and can survive poor workup.

Main End-Uses of Cyclohexenone

The pharmaceutical industry is the main user of cyclohexenone, particularly drug manufacturers, contract manufacturing companies (CDMOs), and pharmaceutical research laboratories. Cyclohexenone is mainly used to make chemical intermediates for drug development and manufacturing. It reacts with chemicals such as amines, thiols, and organocopper compounds to form more complex molecules. It is also used to produce prostaglandins and other pharmaceutical intermediates. Its chemical properties make it useful for producing specialized compounds used in medicine development. Pharmaceutical companies usually buy cyclohexenone in small quantities based on their production needs. Demand can vary, but pharmaceutical-grade cyclohexenone generally sells at higher prices because it requires strict quality checks and testing.

The agrochemical and fine chemical industries are the second major users of cyclohexenone. It is used to produce chemical intermediates for fungicides, insecticides, and plant growth regulators. Cyclohexenone is an important building block in the development of crop protection chemicals. However, some herbicides, such as clethodim and sethoxydim, are often called cyclohexenone herbicides even though they are produced using different chemicals. Including these herbicides in cyclohexenone demand estimates can lead to incorrect market forecasts and production planning.

Cyclohexenone is also used in the flavor, fragrance, insect pheromone, and research industries. Flavor and fragrance manufacturers use it to produce chemicals with fresh, minty, or woody smells. It is also used to make insect attractants and in laboratory research to study chemical reactions and biological processes. Research laboratories use cyclohexenone to study enzymes and how certain chemicals behave in living cells. These industries generally purchase cyclohexenone in small quantities, ranging from grams to kilograms, and contribute a relatively small share of total demand.

Cyclohexenone Market Risks

Cyclohexenone faces several risks because it is a highly toxic specialty chemical with limited market demand. It can be very dangerous if swallowed, inhaled, or absorbed through the skin. It is classified as a hazardous chemical for transportation (UN2929), which limits shipping options and increases transportation costs. Some buyers prefer to manufacture cyclohexenone themselves, use safer alternatives, or purchase other chemical intermediates instead. Since demand comes from a small number of customers, losing a major buyer can significantly affect sales and revenue. Finding new customers can also be difficult and time-consuming. Additionally, low-cost Chinese suppliers create pricing pressure, especially when their product quality is not clearly documented.

Cyclohexenone manufacturing involves several safety and quality risks due to toxic chemicals, unwanted impurities, and fire hazards. During production, other chemicals such as cyclohexenol, peroxides, epoxides, and diols may form along with cyclohexenone. Some peroxide compounds can become unstable and cause fires or explosions if they build up in hot equipment, pipelines, pumps, or storage tanks. Oxygen and solvent vapors can also increase the risk of fire, so proper safety measures are needed. Separating cyclohexenone from cyclohexenol can be difficult because their boiling points are very close. The product can also become darker and form unwanted impurities if it is stored for too long or exposed to light. Workers should wear protective clothing, gloves, face shields, and suitable breathing protection during production, packaging, and equipment maintenance.

Cyclohexenone Production Process and Main Cost Drivers

The cyclohexenone production process runs from cyclohexene receipt through catalytic allylic oxidation, hydroperoxide decomposition, catalyst separation, cyclohexene recovery, conversion of cyclohexenol, vacuum distillation, stabilization, packing under nitrogen, etc.

1. By Liquid-Phase Catalytic Oxidation of Cyclohexene: The main inputs are cyclohexene, oxygen or air, hydrogen peroxide, vanadium, cobalt, iron, or other transition metal catalysts, solvents such as water or acetonitrile, reducing agents for peroxide destruction, nitrogen, and packaging.

Cyclohexene production comes first upstream, and it decides much of the raw material cost. Most cyclohexene is made by partial hydrogenation of benzene over ruthenium catalysts, a process developed by Asahi Kasei and used at large cyclohexanol plants in Japan and China. Cyclohexenone makers buy cyclohexene from those plants or from refinery and chemical traders. Some smaller producers make it by dehydrating cyclohexanol. Cyclohexene price therefore follows benzene, hydrogen, and cyclohexanol market conditions.

The oxidation targets the allylic carbon next to the double bond. Attack on the double bond itself gives an epoxide and diol instead. Industrial practice uses hydrogen peroxide with vanadium catalysts, or oxygen with cobalt, iron, manganese, or similar metal systems. In one published water-based method, an iron- and cobalt-doped carbon nitride catalyst gave 36% conversion and 95% selectivity to cyclohexenone at 90 degree Celsius and 4 MPa oxygen over 15 hours. Low conversion per pass keeps selectivity high, so unreacted cyclohexene is distilled off and recycled. Hydroperoxides are removed using metal catalysts, sulfite or phosphite, or hydrogenation before the material is heated. Cyclohexenol in the crude product can be converted into more cyclohexenone through oxidation or dehydrogenation. Vacuum distillation is then used to obtain cyclohexenone with 97% to 98% purity or higher. The main factors affecting production costs are the process yield, cyclohexene losses during recycling, and peroxide handling.

Main Factors Affecting Cyclohexenone Production Cost

The production cost of cyclohexenone mainly depends on the price of cyclohexene and how efficiently it is converted into the final product. Theoretically, about 0.85 kg of cyclohexene is needed to produce 1 kg of cyclohexenone. When hydrogen peroxide is used, about 0.71 kg of pure hydrogen peroxide is also required. At 95% efficiency, cyclohexene use increases to about 0.90 kg per kilogram of product, before considering recycling losses. Hydrogen peroxide-based methods have higher chemical costs but can operate at lower pressure. Oxygen-based methods have lower chemical costs but require special pressure equipment and additional safety systems.

Other major costs in cyclohexenone production include distillation, catalysts, safety equipment, and packaging. When production efficiency is low, manufacturers need to recycle unused materials, which increases electricity, heating, and cooling costs. Separating cyclohexenone from other chemicals, such as cyclohexenol and cyclohexanone, adds to production costs. Catalyst costs depend on their price, useful life, and ability to be reused. Since cyclohexenone is toxic, plants need special handling equipment, protective clothing, and safety systems. Packaging and transport also increase costs because it is a hazardous chemical, especially for small orders. Batches may fail quality tests due to high peroxide levels, excess cyclohexenol, or changes in color. Some rejected batches can be purified and reused, but this adds to production costs.

Raw Materials for Cyclohexenone Production Plant and its Procurement

Raw material sourcing for cyclohexenone centers on cyclohexene, with oxidants, catalysts, solvents, and packaging alongside. China holds the largest cyclohexene capacity, tied to benzene partial hydrogenation plants that make cyclohexanol for nylon. Japan holds the original Asahi Kasei capacity at its Mizushima complex. Cyclohexene is also sold as a solvent and intermediate by chemical traders. Hydrogen peroxide comes from large anthraquinone process plants in every major region. Its price follows natural gas and hydrogen costs. Oxygen comes from on-site air separation, pipeline supply, or liquid oxygen deliveries, while air suits smaller units with lower oxygen partial pressure.

Raw material quality affects product purity, color, safety, and the production process. Cyclohexene should have low levels of benzene, cyclohexane, peroxides, and sulfur. Older cyclohexene may contain peroxides, so each incoming batch should be tested for peroxides and inhibitors. The hydrogen peroxide grade must also be suitable for the catalyst because some stabilizers can affect metal catalysts. Supply contracts for cyclohexene usually specify assay, peroxide value, water, and benzene limits. Each batch is sampled and tested before use, and suppliers are checked before approval. Having two approved cyclohexene suppliers can help avoid production delays if one supplier faces a plant shutdown in China.

Sustainability and Regulatory Requirements

Cyclohexenone manufacturing has several environmental concerns, including harmful gas emissions, chemical waste, used catalysts, and toxic residues. Gases released during production may contain cyclohexene, cyclohexenone, and solvents, so factories need proper equipment to control air pollution. Wastewater containing chemicals, metal salts, and peroxide residues must be treated before it is released. Used catalysts can be recycled to recover valuable metals or disposed of safely. Regular checks of pumps, valves, and pipelines help prevent leaks and reduce emissions. Leftover chemicals and heavy residues can be safely burned at approved facilities, with energy recovered where possible. Using water-based methods and recycling unused cyclohexene can reduce waste, lower production costs, and improve environmental performance.

Cyclohexenone regulations are based on its classification as a toxic and flammable liquid. Supplier labels may include GHS hazard codes H226, H301, H310, and H330, along with a severe eye irritation warning. Transport follows UN2929 requirements for toxic and flammable organic liquids under ADR, IMDG, IATA, and US DOT rules. In the EU, manufacturers and importers handling more than one tonne per year must register the substance under REACH. In the US, cyclohexenone is covered by TSCA and OSHA hazard communication rules. NTP has conducted inhalation studies in rats and mice, along with micronucleus and Ames tests, which buyers may use for their safety assessments. Pharmaceutical buyers may also require GMP-style change control when cyclohexenone is used in an approved API process.

CAPEX and OPEX for a Cyclohexenone Production Plant

A cyclohexenone manufacturing plant is a small chemical processing facility that uses oxidation and distillation equipment. The major equipment required includes stainless steel or specially coated reactors, chemical dosing systems, oxygen monitoring devices, and safety controls. A cyclohexenone manufacturing plant requires equipment to remove unwanted chemicals, separate liquids, recover unused cyclohexene, and purify the final product. The main equipment includes peroxide treatment vessels, liquid separators, filters, and distillation columns. The plant also needs closed filling systems for drums and intermediate bulk containers (IBCs), along with good ventilation to control harmful vapors. Important utilities include steam, cooling water, refrigeration, nitrogen, vacuum systems, and gas treatment equipment. Quality control laboratories need instruments to test product purity, moisture, peroxide levels, color, and density.

The operating cost of cyclohexenone mainly depends on raw material prices, energy, labor, and safety costs. Other expenses include oxidation chemicals, catalysts, packaging, and equipment maintenance. Recovering unused materials through distillation requires a lot of steam, cooling water, and energy, which increases production costs. Fixed costs include equipment depreciation, safety systems, regulatory approvals, and environmental compliance. Producing related chemicals, such as cyclohexenol, cyclohexene oxide, and substituted cyclohexanones, at the same plant can reduce the cost per kilogram. Planned batch production can reduce cleaning time and operating costs. Good production planning also reduces the need to store toxic chemicals and improves plant safety.

Plant Location and Investment Factors

A suitable location for a cyclohexenone manufacturing plant should be in an established chemical manufacturing hub with easy access to cyclohexene and safe transportation facilities. In China, major locations include Shandong, Henan, Zhejiang, and Jiangsu, where cyclohexanol and nylon-related chemicals are produced. In India, Gujarat and Maharashtra are suitable locations due to their strong chemical industries and access to pharmaceutical and agrochemical customers. Europe and the US are more suitable for smaller-scale production of high-purity cyclohexenone. An ideal plant location should have proper safety systems, emergency response facilities, equipment for treating harmful gases, and trained workers.

For a cyclohexenone manufacturing project, three main factors should be considered, i.e., the production method, raw material supply, and product range. First, manufacturers need to choose between oxygen-based and other oxidation methods. Oxygen-based methods can lower operating costs but require costly equipment and strict safety controls. Second, manufacturers need to decide whether to produce cyclohexene in-house or buy it from suppliers. In-house production is usually cost-effective only at a large scale, so most manufacturers prefer to purchase it. Third, companies can produce related chemicals, such as cyclohexenol, cyclohexene oxide, and substituted ketones, along with cyclohexenone. Producing only cyclohexenone may not be profitable because of limited demand, while producing several related chemicals can help lower costs and improve profitability.

Major Cyclohexenone Producing Regions

China is the largest supplier of cyclohexenone, with many chemical manufacturers and traders supplying it in drums and intermediate bulk containers (IBCs). Japan mainly supplies high-purity cyclohexenone through companies such as TCI and other chemical suppliers. The US has limited domestic production and relies heavily on imports, although companies such as Heico Chemicals have been involved in manufacturing. Europe has suppliers such as Sigma-Aldrich and specialty chemical manufacturers such as Seqens. India also has chemical traders, intermediate manufacturers, and custom synthesis companies that supply cyclohexenone. The main demand comes from the pharmaceutical and agrochemical industries in Europe, the US, India, and China.

Key Cyclohexenone Producers

TCI Chemicals

• Tokyo-based company that manufactures and supplies research and specialty chemicals.
• Offers 2-cyclohexen-1-one under product code C0707, with a minimum purity of 98.0%.
• Competes by offering high-purity products, reliable quality standards, and worldwide distribution.
• Supplies the chemical in 25 mL, 100 mL, and 500 mL bottles under hazardous goods classification UN2929.

Merck KGaA through Sigma-Aldrich

• German science and technology group with the Sigma-Aldrich research chemicals brand.
• Supplies cyclohexenone for research, process development, and small-scale manufacturing.
• Competes on reach, documentation, and quality systems for regulated customers.
• Serves pharmaceutical, academic, and industrial labs worldwide.

Thermo Fisher Scientific

• US laboratory products group that sells chemicals under its Thermo Scientific brand.
• Offers 2-cyclohexen-1-one at 97% purity through Fisher Scientific channels.
• Competes on distribution, lab supply contracts, and broad catalog range.
• Supplies academic and industrial labs in the US, Europe, and Asia.

Seqens

• French pharmaceutical synthesis and specialty ingredients group.
• Listed by The Good Scents Company as a supplier of 2-cyclohexen-1-one.
• Competes on custom synthesis, process chemistry, and European manufacturing.
• Serves pharmaceutical, fragrance, and specialty chemical customers.

Penta International

• New Jersey-based supplier of flavor, fragrance, and specialty chemicals.
• Listed as a supplier of 2-cyclohexen-1-one for flavor and fine chemical buyers.
• Competes on aroma chemical range, small lots, and customer service.
• Serves flavor houses, fragrance makers, and chemical formulators.

Heico Chemicals

• US specialty chemical maker based in Pennsylvania.
• Named in older EPA records reported to the NTP as the only US producer of cyclohexenone.
• Competes in the domestic supply of small-volume specialty intermediates.
• Reported production volumes under 1,000 pounds a year.