2-Phenylphenol Manufacturing Plant Project Report: Key Insights and Outline

2-Phenylphenol Manufacturing Plant Project Report by Procurement Resource thoroughly focuses on every detail that encompasses the cost of manufacturing. Our extensive cost model meticulously covers breaking down 2-Phenylphenol plant capital cost around raw materials, labour, technology, and manufacturing expenses. This enables precise cost structure optimization and helps in identifying effective strategies to reduce the overall 2-Phenylphenol manufacturing plant cost and the cash cost of manufacturing.

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2-Phenylphenol is an organic compound that is a member of the biphenyl family and has effective antimicrobial properties. It is utilised as a fungicide and disinfectant that plays an important role in various industrial and consumer applications. It is widely used as a post-harvest treatment to control fungal and bacterial growth on fruits and vegetables like citrus fruits, apples, and other produce.
 

Industrial Applications of 2-Phenylphenol

2-Phenylphenol works as an effective biocide against bacteria, fungi, and yeasts that makes it useful in many industrial applications:

• Disinfectants and Sanitisers: It is used as active ingredients in different institutional, household, and industrial disinfectants. This includes hospital-grade disinfectants, general-purpose cleaners, and products for sanitation in food processing plants, agricultural settings, and public spaces.
• Post-Harvest Fruit and Vegetable Preservatives: It is applied as a fungicidal wax or dip treatment for citrus fruits, apples, pears, and other produce to prevent ageing during storage and transport. It extends the shelf life of these products and reduces food waste.
• Textile and Dyeing Industry: It works as an antimicrobial agent that prevents mould and mildew growth on textiles in damp environments or during storage. It also finds application as a dye carrier for polyester fibres.
• Industrial Preservatives: It is utilised as a preservative in various industrial formulations that include paints, adhesives, metalworking fluids, and leather processing. It prevents microbial degradation and extends the life of these products.
• Chemical Intermediate: It works as a precursor in the synthesis of other chemicals like speciality resins and many organic compounds.
   

Top 2-Phenylphenol Manufacturers

The market for 2-Phenylphenol is assisted by several global chemical companies known for their speciality chemicals and biocides. The major manufacturers include:

• Lanxess AG: It is a major producer of 2-phenylphenol and utilises it for its disinfectant and material protection applications.
• Dow Chemical Company: It produces 2-phenylphenol and its derivatives for agricultural and disinfectant uses.
• Tokyo Chemical Industry Co., Ltd.: It provides 2-phenylphenol for labouratory and specific industrial uses.
• Sigma-Aldrich: Sigma-Aldrich delivers high-purity 2-phenylphenol for R&D and specialised applications.
• Shandong Xingang Chemical Co., Ltd.: This company has emerged as a significant producer and serves both domestic and international markets.
   

Feedstock for 2-Phenylphenol

The manufacturing process for 2-Phenylphenol involves a catalytic dimerisation and hydrogenation that uses the following feedstocks:

• Cyclohexanone (C6H10O): Cyclohexanone is produced by the oxidation of cyclohexane or the hydrogenation of phenol. Its industrial procurement cost is influenced by the prices of crude oil (which impacts cyclohexane and benzene, a precursor to phenol) and natural gas (for hydrogen production).
• Base Catalyst (like Sodium Hydroxide (NaOH), Potassium Hydroxide (KOH)): They are produced via chlor-alkali electrolysis. Their prices are generally stable but can be influenced by energy costs (for electrolysis) and demand from various industries like pulp and paper, textiles, and water treatment.
• Hydrogen Gas (H2): Hydrogen is produced via steam methane reforming (SMR) or as a by-product of chlor-alkali processes. The production cost analysis of hydrogen is directly affected by the prices of natural gas. The cost of hydrogen also includes compression, storage, and safe handling.
• Hydrogenation Catalyst (e.g., Raney Nickel, Palladium on Carbon (Pd/C)): Raney Nickel is a low-cost base metal catalyst, while Palladium is a precious metal that can have fluctuation in its market price, which can impact the capital investment costs.

The value chain for 2-Phenylphenol covers crude oil and natural gas extraction, through petrochemical refining to produce cyclohexanone, and commodity chemical production for the base and hydrogen.
 

Market Drivers for 2-Phenylphenol

The market for 2-Phenylphenol is driven by several factors:

• Growing Demand for Disinfectants: The rise in global awareness over hygiene and sanitation drives demand for effective disinfectants in healthcare, residential, and commercial sectors.
• Food Preservation: Growing global population and the need to reduce food waste fuel the demand for effective post-harvest treatments in fruits and vegetables.
• Industrial Growth: The rising industries like textiles, paints and coatings, and leather in emerging economies contribute to its demand for the synthesis of industrial preservatives.
• Regulatory Landscape: The evolution in environmental and health regulations further impacts production and usage, which affects regional demand.
• Geographical Consumption: It is largely consumed in regions with strong chemical manufacturing, food processing, and healthcare sectors that includes North America, Europe, and the Asia-Pacific region, because of rapid industrialisation and population growth.
   

CAPEX and OPEX for 2-Phenylphenol Manufacturing Plant

Capital Expenditure (CAPEX)

The 2-Phenylphenol plant capital cost includes the initial investment cost for setting up the production facility, and the major components include:

• Land and Site Development: Purchasing of industrial land, site grading, utility connections (power, water, gas, drainage), and necessary environmental permits.
• Process Equipment: This covers a large portion of the capital investment costs:
• Dimerisation Reactor: A stirred tank reactor (stainless steel or glass-lined) that can handle alkaline conditions and controlled heating for the initial dimerisation of cyclohexanone.
• Hydrogenation Reactor (Hydrogenator): A specialised pressure vessel designed to handle hydrogen gas under high temperature and pressure (equipped with an agitator and internal cooling coils).
• Hydrogen Generation/Storage Unit: If hydrogen is generated on-site (e.g., SMR unit) or large-scale storage cylinders/tanks for purchased hydrogen.
• Catalyst Preparation/Handling Equipment: For preparing and introducing the base catalyst and hydrogenation catalyst.
• Filtration Units: For separating the catalyst from the hydrogenated product and for product purification steps (like rotary vacuum filters, centrifuges, etc.).
• Distillation Columns/Evaporators: For separating 2-phenylphenol from unreacted materials, byproducts, and solvents. This typically involves multiple stages of distillation because of the boiling point of the product.
• Crystallisers: For forming solid 2-Phenylphenol crystals from the purified solution.
• Dryers: To remove residual moisture from the crystalline product.
• Pumps, Heat Exchangers, and Piping: A Proper network for material transfer and temperature management throughout the plant.
• Utilities Infrastructure: Systems for steam generation (boilers), cooling water, chilled water, compressed air, nitrogen (inert atmosphere), and strong electrical power distribution.
• Instrumentation and Control Systems: DCS or PLC systems for precise control of temperature, pressure, flow rates, and reactant addition that include sensors, analysers (e.g., GC, HPLC for quality control), etc.
• Safety and Environmental Systems: Fire detection and suppression systems, explosion-proof equipment (especially in hydrogen areas), ventilation, emergency showers, effluent treatment plants (for wastewater and solid waste), and air pollution control equipment. Compliance with regulations significantly impacts capital investment costs.
• Building and Civil Works: Construction of the main production building, control room, labouratory, warehousing for raw materials and finished goods, and administrative offices.
• Engineering and Project Management: Costs for detailed engineering design, project oversight, and technology licensing fees from a technology provider for specific dimerisation or hydrogenation processes.
• Contingency: A crucial fund for unexpected expenses during project execution.
   

Operating Expenses (OPEX)

Operating expenses (OPEX) are the ongoing costs of running the facility, which directly impact the cash cost of production and cost per metric ton (USD/MT).

• Raw Materials: The largest component of manufacturing expenses. This includes the industrial procurement cost of cyclohexanone, base catalyst, hydrogen gas, and hydrogenation catalyst. Market price fluctuation of these inputs largely affects OPEX.
• Utilities: Consumption of electricity, natural gas (for steam generation and hydrogen production), water, and inert gases. Energy efficiency initiatives are key for cost structure optimisation.
• Labour Costs: Salaries and benefits for plant operators, maintenance crew, quality control personnel, chemists, engineers, and administrative staff. Production efficiency metrics of the workforce influence these costs.
• Catalyst Replacement/Regeneration: Ongoing costs for replacing spent hydrogenation and dimerisation catalysts, or for their regeneration (if applicable), which can be a significant manufacturing expense, especially for precious metal catalysts.
• Maintenance and Repairs: Routine upkeep, preventive maintenance, spare parts, and unforeseen equipment repairs to ensure smooth operation.
• Waste Treatment and Disposal: Costs associated with managing and safely disposing of spent catalysts, process wastewater, and other solid or liquid byproducts. Environmental compliance costs can be substantial.
• Quality Control and Assurance: Expenses for labouratory testing, analytical equipment calibration, and personnel to ensure the product meets specifications.
• Depreciation and Amortisation: Non-cash expenses that present the consumption of capital assets over their useful life, factored into the cost of goods sold (COGS).
• Administrative and Overhead: Insurance, property taxes, R&D, sales & marketing, and general corporate overhead.
• Technology Licensing Fees (Operational Component): Any ongoing royalties or maintenance fees associated with licensed production technologies.

A comprehensive production cost analysis integrates both fixed and variable costs to determine the break-even point and evaluate the return on investment (ROI). Continuous supply chain optimisation for raw materials and energy efficiency is critical for maintaining competitive manufacturing expenses.

• 2-Phenylphenol Manufacturing Process: Catalytic Dimerisation and Hydrogenation

This report comprises a thorough value chain evaluation for 2-Phenylphenol manufacturing and consists of an in-depth production cost analysis revolving around industrial 2-Phenylphenol manufacturing. The industrial manufacturing process details the transformation of readily available raw materials into the desired product.
 

Catalytic Dimerisation and Hydrogenation Process

The production process of 2-phenylphenol involves catalytic dimerisation and hydrogenation. The process starts with the dimerisation of cyclohexanone in the presence of a base as a catalyst that forms 2-cyclohexylidenecyclohexanone. This reaction typically involves heating cyclohexanone with a small amount of a strong base (e.g., sodium hydroxide), to leads to aldol condensation and forms a dimeric intermediate. This intermediate goes through hydrogenation that saturates the carbon-carbon double bond and leads to aromatisation of one of the rings through dehydrogenation, resulting in the formation of 2-Phenylphenol as the final product.
 

Properties of 2-Phenylphenol

2-Phenylphenol is an organic compound that has a molecular formula C12H10O and a molecular weight of 170.21 g/mol. The following physical and chemical properties make it useful in a range of applications.

• Physical Properties:
  • White/off-white crystalline solid or flakes.
  • Faint phenolic odour.
  • Melting point: 56-58 degree Celsius
  • Boiling point: 286 degree Celsius
  • Sparingly soluble in water; soluble in organic solvents (alcohols, ethers, ketones, aromatic hydrocarbons).
• Chemical Properties:
  • Weakly acidic (phenol structure).
  • Broad-spectrum antimicrobial activity (bacteria, fungi, some viruses).
  • Stable under normal conditions; degrades under light or high heat.
  • Can undergo electrophilic aromatic substitution and alkylation/acylation.
• Safety: Mild irritant to skin/eyes, harmful if swallowed; requires safety precautions during handling.

The specific properties of 2-Phenylphenol make it a highly effective and versatile biocide, driving consistent demand across critical industries, emphasising the need for efficient 2-Phenylphenol manufacturing plant cost and cost structure optimisation to maintain market competitiveness.

We at Procurement Resource ensure that this report is not only cost-efficient, environmentally sustainable, and aligned with the latest technological advancements but also that you are equipped with all necessary tools to optimize supply chain operations, manage risks effectively, and achieve superior market positioning for 2-Phenylphenol.
 

Key Insights and Report Highlights

Key Questions Covered in our 2-Phenylphenol Manufacturing Plant Report

• How can the cost of producing 2-Phenylphenol be minimized, cash costs reduced, and manufacturing expenses managed efficiently to maximize overall efficiency?
• What is the estimated 2-Phenylphenol manufacturing plant cost?
• What are the initial investment and capital expenditure requirements for setting up a 2-Phenylphenol manufacturing plant, and how do these investments affect economic feasibility and ROI?
• How do we select and integrate technology providers to optimize the production process of 2-Phenylphenol, and what are the associated implementation costs?
• How can operational cash flow be managed, and what strategies are recommended to balance fixed and variable costs during the operational phase of 2-Phenylphenol manufacturing?
• How do market price fluctuations impact the profitability and cost per metric ton (USD/MT) for 2-Phenylphenol, and what pricing strategy adjustments are necessary?
• What are the lifecycle costs and break-even points for 2-Phenylphenol manufacturing, and which production efficiency metrics are critical for success?
• What strategies are in place to optimize the supply chain and manage inventory, ensuring regulatory compliance and minimizing energy consumption costs?
• How can labour efficiency be optimized, and what measures are in place to enhance quality control and minimize material waste?
• What are the logistics and distribution costs, what financial and environmental risks are associated with entering new markets, and how can these be mitigated?
• What are the costs and benefits associated with technology upgrades, modernization, and protecting intellectual property in 2-Phenylphenol manufacturing?
• What types of insurance are required, and what are the comprehensive risk mitigation costs for 2-Phenylphenol manufacturing?