Diisopropyl Adipate Manufacturing Plant Project Report: Key Insights and Outline

Diisopropyl Adipate 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 Diisopropyl Adipate 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 Diisopropyl Adipate manufacturing plant cost and the cash cost of manufacturing.

Planning to Set Up a Diisopropyl Adipate Plant? Request a Free Sample Project Report Now!
 

Diisopropyl Adipate (DIPA) is a speciality ester that has emollient, solvent, and spreading properties. It is utilised in cosmetics, personal care, and pharmaceutical industries. It has a non-greasy feel, excellent spreadability on skin, and ability to solubilise various active ingredients and UV filters, which makes it useful in the production of lotions, creams, sunscreens, and hair care products.
 

Industrial Applications of Diisopropyl Adipate

Diisopropyl Adipate has various industrial applications because of its usage as an emollient, solvent, and spreading agent. 

• Cosmetics and Personal Care:
  • Emollient: It provides a lightweight, non-greasy, and silky feel to skin in lotions, creams, moisturisers, and body oils.
  • Solvent and Carrier: It works as a solvent for various active ingredients, fragrances, and UV filters in sunscreens, hairsprays, and deodorants.
  • Spreading Agent: It improves the spreadability of formulations on the skin.
  • Hair Conditioning: It is used in conditioners and styling products to impart shine and manageability without heavy residue.
• Pharmaceuticals: It works as a solvent, emollient, or vehicle in topical pharmaceutical formulations.
   

Top Industrial Manufacturers of Diisopropyl Adipate

The production of diisopropyl adipate is done by major global speciality chemical companies that focus on esters and emollients for the personal care and pharmaceutical industries.

• BASF SE
• Croda International Plc
• Ashland Global Holdings Inc.
• Stepan Company
• Evonik Industries AG
   

Feedstock for Diisopropyl Adipate and its Market Dynamics

The major raw materials for diisopropyl adipate production are adipic acid and isopropanol.

• Adipic Acid: It is produced by the oxidation of cyclohexane (derived from benzene, a petrochemical) with nitric acid or air. The price of adipic acid is influenced by crude oil prices (via benzene/cyclohexane) and natural gas prices (for nitric acid production). Also, its demand from its major industries (like nylon 6,6, polyurethanes, plasticisers) influences its price.
• Isopropanol: It is produced by the hydration of propylene (a petrochemical) or by the hydrogenation of acetone (derived from propylene oxidation). Propylene is a major olefin from steam cracking or fluid catalytic cracking. The price of isopropanol is affected by crude oil prices (via propylene) and demand from industries like solvents, disinfectants, and chemical intermediates. Its price also depends on the overall supply-demand balance in the petrochemical industry.
   

Market Drivers for Diisopropyl Adipate

The market for diisopropyl adipate is influenced by several factors:

• Booming Cosmetics and Personal Care Industry: The growth in cosmetics, skincare, sun care, and hair care products contributes to its demand as an emollient and spreading agent.
• Demand for Sunscreens and UV Filters: The growing awareness of sun protection boosts demand for sunscreens, making it a popular product.
• Focus on Skin-Friendly and Non-Irritating Ingredients: Its safety and sensory profile make it a preferred choice for a mild, non-comedogenic, and non-irritating formulation.
• Technological Advancements: Improvements in esterification processes ( like catalyst development, efficient water removal) improve production efficiency.
• Geographical Market Dynamics:
  • Asia-Pacific (APAC): The market for this region is driven by the growing market for emollients, driven by its massive population, and expanding domestic personal care industries.
  • North America and Europe: The market of these regions is supported by mature cosmetics markets, a strong focus on high-performance and speciality formulations, and strict regulatory standards for product safety.
     

Capital and Operational Expenses for a Diisopropyl Adipate Plant

Setting up a Diisopropyl Adipate manufacturing plant involves a significant total capital expenditure (CAPEX) and careful management of ongoing operating expenses (OPEX). A detailed cost model and production cost analysis are crucial for determining economic feasibility and optimising the overall Diisopropyl Adipate plant cost. Given the use of acids, high temperatures, and flammable isopropanol, robust engineering and safety systems are essential.
 

CAPEX: Comprehensive Diisopropyl Adipate Plant Capital Cost

The total capital expenditure (CAPEX) for a Diisopropyl Adipate plant covers all fixed assets required for the esterification reaction, separation, and purification. This is a major component of the overall investment cost.

• Site Acquisition and Preparation (5-8% of Total CAPEX):
  • Land Acquisition: Purchasing suitable industrial land, preferably near feedstock suppliers and with access to utilities and transportation. Requires consideration for safety distances for flammable isopropanol.
  • Site Development: Foundations for reactors, distillation columns, and tanks, internal roads, drainage systems, and high-capacity utility connections (power, water, steam).
• Raw Material Storage and Handling (10-15% of Total CAPEX):
  • Adipic Acid Storage: Silos or hoppers for solid adipic acid powder, with conveying systems.
  • Isopropanol Storage: Flammable-liquid storage tanks for isopropanol, requiring fire protection, inert gas blanketing, and vapour recovery systems. Includes precise metering pumps and transfer lines.
  • Catalyst Storage: Tanks for sulfuric acid (catalyst), requiring corrosion-resistant materials and safe dosing pumps.
  • Caustic Soda/Neutralising Agent Storage: Tanks for caustic soda solution (for neutralisation), with appropriate pumping systems.
• Reaction Section (20-30% of Total CAPEX):
  • Esterification Reactor: A jacketed, agitated reactor (e.g., stainless steel or glass-lined steel) designed for the reaction of adipic acid with isopropanol. It must withstand elevated temperatures (e.g., 100-150 degree Celsius) and the corrosive nature of the acid catalyst. Requires efficient heating/cooling systems and reflux condensers. This is central to the Diisopropyl Adipate manufacturing plant cost.
  • Water Removal System: Equipment (e.g., decanter, phase separator, vacuum system) for continuous removal of water formed during the esterification to drive the reaction to completion. This often involves azeotropic distillation with isopropanol.
• Separation and Purification Section (25-35% of Total CAPEX):
  • Neutralisation Tanks: For neutralising the sulfuric acid catalyst after the reaction, typically using an alkaline solution (e.g., caustic soda solution).
  • Washing Tanks: Agitated vessels for washing the crude Diisopropyl Adipate with water to remove soluble impurities (salts, excess acid, unreacted reactants).
  • Decanters/Liquid-Liquid Separators: To efficiently separate the organic Diisopropyl Adipate layer from the aqueous wash layers.
  • Distillation Columns: A series of high-efficiency vacuum distillation columns is essential for purifying Diisopropyl Adipate. This involves separating excess isopropanol (for recycling) and any minor by-products. Vacuum distillation is commonly used due to DIPA's relatively high boiling point (approx. 250 degree Celsius).
  • Reboilers and Condensers: Extensive heat exchange equipment for energy-intensive distillation.
  • Solvent Recovery System: For recovering and recycling isopropanol from various streams (e.g., washing, distillation).
• Finished Product Storage and Packaging (5-8% of Total CAPEX):
  • Storage Tanks: For purified Diisopropyl Adipate, typically stainless steel.
  • Packaging Equipment: Pumps, filling machines for drums, IBCs, or bulk tanker loading systems.
• Utility Systems (10-15% of Total CAPEX):
  • Steam Generation: Boilers for providing steam for heating reactors, distillation columns, and evaporators.
  • Cooling Water System: Cooling towers and pumps for process cooling and condensation.
  • Electrical Distribution: Explosion-proof electrical systems in areas handling flammable isopropanol.
  • Compressed Air System: For instrumentation and pneumatic actuators.
  • Wastewater Treatment Plant: Facilities for treating acidic/alkaline wastewater streams (containing salts, residual organics).
• Automation and Instrumentation (5-10% of Total CAPEX):
  • Distributed Control System (DCS) / PLC systems for precise monitoring and control of temperature, pH, pressure, and flow.
• Analysers for in-process quality control.
• Quality Control Laboratory: Equipped for rigorous chemical and physical testing to ensure product specifications are met for personal care and pharmaceutical applications.
• Engineering, Procurement, and Construction (EPC) Costs (10-15% of Total CAPEX):
  • Includes detailed process design, material sourcing, construction of compliant facilities, and rigorous commissioning.

The aggregate of these components defines the total capital expenditure (CAPEX), significantly impacting the initial Diisopropyl Adipate plant capital cost and the viability of the investment cost.
 

OPEX: Detailed Manufacturing Expenses and Production Cost Analysis

Operating expenses (OPEX) are the recurring manufacturing expenses necessary for the continuous production of Diisopropyl Adipate. These costs are crucial for the production cost analysis and determining the cost per metric ton (USD/MT) of DIPA.

• Raw Material Costs (Approx. 50-70% of Total OPEX):
  • Adipic Acid: Major raw material expense. Its cost is influenced by crude oil/benzene prices. Strategic industrial procurement is vital to manage its market price fluctuation.
  • Isopropanol: Significant cost, influenced by propylene prices. Efficient recycling is critical for cost control.
  • Sulfuric Acid (Catalyst): Cost of sulfuric acid and its replenishment.
  • Caustic Soda (for Neutralisation): Cost of caustic soda solution.
  • Process Water: For reaction, washing, and utilities.
• Utility Costs (Approx. 15-25% of Total OPEX):
  • Energy: Primarily steam for heating reactors and distillation/evaporation, and electricity for pumps, agitators, and process control.
  • Cooling Water: For process cooling.
  • Natural Gas/Fuel: For boiler operation.
• Labour Costs (Approx. 8-15% of Total OPEX):
  • Salaries, wages, and benefits for operators, maintenance staff, and QC personnel.
• Maintenance and Repairs (Approx. 3-6% of Fixed Capital):
  • Routine preventative maintenance programs, unscheduled repairs, and replacement of parts for reactors (especially those handling acids and high temperatures), distillation columns, and pumps.
• Waste Management and Environmental Compliance (2-4% of Total OPEX):
  • Costs associated with treating and disposing of acidic/alkaline wastewater streams (containing salts, residual organics) and managing any air emissions (e.g., isopropanol vapours). Compliance with environmental regulations is crucial.
• Depreciation and Amortisation (Approx. 5-10% of Total OPEX):
  • Non-cash expenses that account for the wear and tear of the total capital expenditure (CAPEX) assets over their useful life.
• Indirect Operating Costs (Variable):
  • Insurance premiums, property taxes, and expenses for research and development aimed at improving production efficiency metrics or exploring new cost structure optimisation strategies.
• Logistics and Distribution: Costs for transporting raw materials to the plant and finished Diisopropyl Adipate to customers, often requiring bulk liquid handling.

Effective management of these operating expenses (OPEX) through continuous process improvement, efficient industrial procurement of feedstock, and stringent quality control is paramount for ensuring the long-term profitability and competitiveness of Diisopropyl Adipate manufacturing.
 

Diisopropyl Adipate Industrial Manufacturing Process

This report comprises a thorough value chain evaluation for Diisopropyl Adipate manufacturing and consists of an in-depth production cost analysis revolving around industrial Diisopropyl Adipate manufacturing. The process relies on a direct esterification reaction.
 

Preparation from Adipic Acid:

The manufacturing for diisopropyl adipate involves an esterification reaction. In this reaction, adipic acid is reacted with isopropanol in the presence of an acid catalyst. The reactants are combined in a heated reactor, where esterification takes place, forming diisopropyl adipate and water. After the reaction, the mixture is neutralised and washed, and the product is separated from the mixture and further purified to give pure diisopropyl adipate as the final product.
 

Properties of Diisopropyl Adipate

Diisopropyl Adipate is the diester of adipic acid and isopropanol that has two isopropyl ester groups linked by a flexible six-carbon chain. It has several physical and chemical properties that make it useful in industrial applications as an emollient and solvent.
 

Physical Properties

• Appearance: Clear, colourless, and odourless liquid.
• Odor: Odorless.
• Boiling Point: ~250–252 degree Celsius.
• Melting Point: ~–10 degree Celsius.
• Density: ~0.950–0.955 g/mL.
• Solubility: Insoluble in water; soluble in ethanol, isopropanol, ethers, and hydrocarbons
• Spreading Value: Excellent.
• Flash Point: ~125 degree Celsius (closed cup).
   

Chemical Properties

• Diester Structure: Contains two isopropyl ester groups; hydrolyses under strong acid/base or high heat.
• Hydrolysis Products: Adipic acid and isopropanol.
• Formulation Compatibility: Non-polar, stable, compatible with a wide range of cosmetic ingredients without instability.
• Stability: Resistant to oxidation and discolouration, stable under normal conditions.
• Non-Comedogenic: Does not block pores, suitable for skincare products.
   

Diisopropyl Adipate Manufacturing Plant Report provides you with a detailed assessment of capital investment costs (CAPEX) and operational expenses (OPEX), generally measured as cost per metric ton (USD/MT). This approach ensures that your investment decisions are aligned with the latest industry standards and economic feasibility metrics, enhancing your manufacturing efficiency and financial planning.

Apart from that, this Diisopropyl Adipate manufacturing plant report also covers the leading technology providers that help you plan a robust plan of action related to Diisopropyl Adipate manufacturing plant and its production process(es), and also by helping you with an in-depth supplier database. This report provides exclusive insights into the best manufacturing practices for Diisopropyl Adipate and technology implementation costs. This report also covers operational cash flow, fixed and variable costs, and detailed break-even point analysis, ensuring that your manufacturing process is not only efficient but also economically viable in the competitive market landscape.

In addition to operational insights, the Diisopropyl Adipate manufacturing plant report also comprehensively focuses on lifecycle cost analysis, maintenance costs, and energy consumption costs, which are critical for maintaining long-term sustainability and profitability. Our manufacturing cost analysis extends to include regulatory compliance costs, inventory holding costs, and logistics and distribution costs, providing a holistic view of the potential expenses and savings.

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 Diisopropyl Adipate.
 

Key Insights and Report Highlights

Key Questions Covered in our Diisopropyl Adipate Manufacturing Plant Report

• How can the cost of producing Diisopropyl Adipate be minimized, cash costs reduced, and manufacturing expenses managed efficiently to maximize overall efficiency?
• What is the estimated Diisopropyl Adipate manufacturing plant cost?
• What are the initial investment and capital expenditure requirements for setting up a Diisopropyl Adipate 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 Diisopropyl Adipate, 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 Diisopropyl Adipate manufacturing?
• How do market price fluctuations impact the profitability and cost per metric ton (USD/MT) for Diisopropyl Adipate, and what pricing strategy adjustments are necessary?
• What are the lifecycle costs and break-even points for Diisopropyl Adipate 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 labor 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 Diisopropyl Adipate manufacturing?
• What types of insurance are required, and what are the comprehensive risk mitigation costs for Diisopropyl Adipate manufacturing?