Metanilic Acid Manufacturing Plant Project Report: Key Insights and Outline

Metanilic Acid 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 Metanilic Acid plant capital cost around raw materials, labour, technology, and manufacturing expenses. This enables precise cost structure optimisation and helps in identifying effective strategies to reduce the overall Metanilic Acid manufacturing plant cost and the cash cost of manufacturing.

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Metanilic Acid is an organic compound that appears as a white to beige powder. It is an important intermediate in the chemical industry, mainly utilised for its role in dye manufacturing, pharmaceuticals, and agrochemicals due to its reactive amino and sulfonic acid groups.
 

Industrial Applications

• Dye Industry (Major Use):
  • Azo Dyes: It functions as an intermediate in the synthesis of a wide range of azo dyes, which are used in the textile industry for colouring fabrics, leather, and paper. It contributes to achieving vibrant colours and ensuring dye stability and durability.
  • Optical Brightening Agents: It can also be used in the production of certain optical brightening agents that enhance the whiteness and brightness of textiles and paper.
• Pharmaceutical Industry:
  • Synthesis of Drugs: It serves as a precursor in the synthesis of various pharmaceutical compounds. Its chemical properties make it valuable in creating compounds with specific therapeutic effects, which highlights its importance in medical advancements. It is also favoured for its potential antipyretic and analgesic properties in some formulations.
• Agrochemicals Sector:
  • Pesticides & Herbicides: It is also utilised as a major component in the production of certain pesticides and herbicides within the agrochemical sector, contributing to formulations that enhance agricultural productivity.
• Chemical Intermediate:
  • It serves as an essential intermediate in the production of various other chemicals, such as some quinoline derivatives and intermediates for fluorescent brightening agents.
     

Top 5 Industrial Manufacturers of Metanilic Acid

• Sadhana Nitro Chemical Ltd. (India)
• Chemwill Asia (China)
• DAYANG CHEM (China)
• Finetech Industry Limited (China)
• J&H CHEM (China)
• Alfa Aesar (part of Thermo Fisher Scientific, USA)
   

Feedstock for Metanilic Acid

A comprehensive production cost analysis for Metanilic Acid is influenced by the availability, pricing, and secure industrial procurement of its primary raw materials such as m-nitrobenzene sulfonic acid and iron metal. Strategic sourcing is fundamental for managing manufacturing expenses and ensuring long-term economic feasibility.

• M-Nitrobenzene Sulfonic Acid (Major Feedstock):
  • Source: m-Nitrobenzene sulfonic acid (often used as its sodium salt) is mainly produced by the sulfonation of nitrobenzene using oleum (sulfur trioxide in sulfuric acid) at elevated temperatures. Nitrobenzene itself is derived from the nitration of benzene, a petrochemical.
  • The price of m-nitrobenzene sulfonic acid is linked to the cost of its precursor, nitrobenzene, which in turn is influenced by the volatile prices of crude oil (for benzene) and nitric acid. The costs and availability of these inputs directly impact the pricing and availability of metanilic acid.
• Iron Metal (Reducing Agent):
  • Source: Iron metal, mainly used in powder or fine particulate form, is readily available from steel manufacturing processes or dedicated metal powder production.
  • The price of iron metal powder is relatively stable compared to petrochemicals but is influenced by global steel and metal markets. The quantity of iron consumed and the management of iron oxide by-products significantly impact overall manufacturing expenses for metanilic acid.
• Hydrochloric Acid (Catalyst/Acid Source):
  • Source: Hydrochloric acid (HCl) is a common industrial chemical, often produced as a co-product of chlor-alkali processes or from the direct reaction of hydrogen and chlorine.
  • The cost of hydrochloric acid is influenced by electricity prices (for chlor-alkali), demand for its co-products (e.g., caustic soda), and the availability of elemental chlorine. Its role in the reaction as a catalyst and to maintain acidic conditions directly impacts the process efficiency and overall production cost analysis.

Understanding these detailed feedstock dynamics, mainly the reliance on petrochemical derivatives and the management of co-product availability, is required for precisely determining the cash cost of production and assessing the overall economic feasibility of Metanilic Acid manufacturing.
 

Market Drivers for Metanilic Acid

The market for Metanilic Acid is driven by its essential roles in key industrial sectors, influencing consumption patterns, demand trends, and strategic geo-locations for production.

• Growing Textile & Dye Industry: The global fashion and apparel industry's continuous growth leads to a rising demand for high-quality dyes and pigments. Metanilic Acid, as an important intermediate for azo dyes, directly benefits from this trend, ensuring vibrant and durable colours in fabrics, textiles, and leather products.
• Expansion of Pharmaceutical Sector: The pharmaceutical industry is increasingly utilising Metanilic Acid for the synthesis of various pharmaceutical compounds. The global rise in healthcare needs, coupled with rising in research and development activities and the production of generic medications, which boosts the market growth for Metanilic Acid as a building block in drug formulation.
• Increasing Demand in Agrochemicals: The global push for increased agricultural productivity to ensure food security leads to a heightened focus on chemical inputs. Metanilic Acid's role as a vital component in the production of pesticides and herbicides directly supports this demand.
• Industrialisation & Manufacturing Growth: The overall expansion of chemical manufacturing industries, where Metanilic Acid serves as a versatile intermediate for various organic compounds, contributes to its sustained market growth.
   

Regional Market Drivers:

• Asia-Pacific: This region has a huge demand for metanilic acid driven by its massive textile industry (especially in China and India) and rapidly expanding pharmaceutical and agrochemical sectors. The continuous industrialisation and urbanisation across the region fuel a high demand for dyes, medicines, and agricultural inputs, which makes Asia-Pacific a primary location for new metanilic acid plant capital cost investments.
• Europe: This region has a major demand for metanilic acid, mainly from its established speciality chemical, pharmaceutical, and high-value textile industries. The region's stringent quality standards for dyes and pharmaceutical intermediates, coupled with ongoing innovation in these sectors, ensure consistent consumption.
• North America: North America's demand for metanilic acid is driven by its strong pharmaceutical industry, advanced agrochemical sector, and specialised chemical manufacturing. New metanilic acid manufacturing plant cost projects here prioritise advanced technologies and niche applications to serve specific industrial needs.
   

Capital Expenditure (CAPEX) for a Metanilic Acid Manufacturing Facility

Setting up a Metanilic Acid manufacturing plant involves substantial capital expenditure. This initial investment directly impacts the overall metanilic acid plant cost and is also necessary for evaluating long-term economic feasibility.

• Reaction Section Equipment:
  • Reduction Reactors: It includes major investment in robust, agitated reactors, typically constructed from stainless steel or lined carbon steel, capable of handling acidic conditions (hydrochloric acid) and exothermic reactions.
  • Feedstock Addition Systems: Automated systems for precise and controlled feeding of solid m-nitrobenzene sulfonic acid (or its solution), iron metal powder, and liquid hydrochloric acid into the reactor.
• Product Separation & Purification:
  • Filtration Units: Industrial filter presses or rotary vacuum filters are essential for separating the solid Metanilic Acid product from the reaction slurry and removing spent iron oxide (iron sludge) by-product.
  • Washing Systems: Tanks and pumps for washing the filtered Metanilic Acid cake to remove residual impurities, unreacted acid, and iron salts.
  • Drying Equipment: Industrial dryers such as fluid bed dryers, rotary dryers, or vacuum tray dryers for drying the purified Metanilic Acid powder to achieve the desired moisture content and stability.
• Raw Material Storage & Handling Systems:
  • M-Nitrobenzene Sulfonic Acid Storage: Silos or storage bins for solid m-nitrobenzene sulfonic acid, or tanks for its aqueous solution.
  • Iron Metal Storage: Dry, segregated storage facilities for iron metal powder to prevent oxidation.
  • Hydrochloric Acid Storage: Corrosion-resistant storage tanks (e.g., fibreglass reinforced plastic, lined steel) for concentrated hydrochloric acid.
  • All storage areas and handling systems incorporate appropriate safety measures for corrosive and acidic materials.
• Off-Gas Treatment & Scrubber Systems:
  • The reduction reaction can produce hydrogen (from the iron reaction with acid) and other volatile components. This involves multi-stage wet scrubbers (e.g., caustic scrubbers) to neutralise any acidic fumes (HCl) or other gaseous emissions before release.
• Pumps & Piping Networks:
  • Consists of networks of robust, chemical-resistant pumps and piping (e.g., stainless steel, PTFE-lined, FRP) suitable for safely transferring acidic slurries, solutions, and corrosive liquids throughout the process.
• Wastewater Treatment Plant (ETP):
  • Includes facilities to handle acidic wastewater from washing and filtration, and to manage the iron-containing sludge by-product, ensuring compliance with environmental discharge standards.
• Utilities & Support Infrastructure:
  • Steam generation (boilers) for heating, cooling water systems (with cooling towers) for reaction temperature control, and compressed air systems.
• Instrumentation & Process Control:
  • It consists of a sophisticated Distributed Control System (DCS) or advanced PLC system with Human-Machine Interface (HMI) for automated monitoring and precise control of all critical process parameters (temperature, pH, reactant addition rates, agitation), ensuring optimal reaction conversion and safety.
• Safety & Emergency Systems:
  • Includes fire detection and suppression systems, emergency shutdown (ESD) systems, chemical leak detection (especially for acids), emergency showers/eyewash stations, and extensive personal protective equipment (PPE) for personnel.
• Laboratory & Quality Control Equipment:
  • A fully equipped analytical laboratory with advanced instruments such as High-Performance Liquid Chromatography (HPLC) for purity and impurity analysis, UV-Vis spectrophotometers for concentration, titration equipment for acid content, and moisture analysers.
• Civil Works & Buildings:
  • Costs associated with land acquisition, site preparation, foundations, and construction of specialised reaction buildings, filtration and drying sections, raw material storage facilities, product warehousing, administrative offices, and utility buildings.
     

Operating Expenses (OPEX) for a Metanilic Acid Manufacturing Facility

• Raw Material Costs (Highly Variable): It includes the purchase price of m-nitrobenzene sulfonic acid, iron metal (powder), and hydrochloric acid.
• Utilities Costs (Variable): Significant variable costs include electricity consumption for agitation, pumps, filtration, dryers, and control systems. Energy for heating (e.g., for reaction temperature control) and cooling (e.g., for post-reaction cooling) also contribute to the utility costs.
• Labour Costs (Semi-Variable): This includes wages, salaries, and benefits for the entire plant workforce, including process operators, chemical engineers, maintenance technicians, and quality control personnel.
• Maintenance & Repair Costs (Fixed/Semi-Variable): Ongoing expenses for routine preventative and predictive maintenance, calibration of instruments, and proactive replacement of consumable parts (e.g., pump seals, filter media, reactor linings). The corrosive nature of hydrochloric acid and acidic process conditions necessitates specialised, more expensive materials of construction.
• Chemical Consumables (Variable): Costs for neutralising agents (e.g., lime or caustic soda for ETP), flocculants for sludge treatment, and laboratory consumables for ongoing process and quality control.
• Waste Treatment & Disposal Costs (Variable): These are often very significant expenses due to the generation of iron oxide sludge (a solid waste containing iron salts) and acidic wastewater.
• Quality Control Costs (Fixed/Semi-Variable): Expenses for the reagents, consumables, and labour involved in continuous analytical testing to ensure the high purity, specific isomer content (meta-isomer), and critical properties of the final Metanilic Acid product.
• Administrative & Overhead (Fixed): General business expenses, including plant administration salaries, insurance premiums, property taxes, and ongoing regulatory compliance fees.
• Interest on Working Capital (Variable): The cost of financing the day-to-day operations, including managing raw material inventory and in-process materials, impacts the overall cost model.
   

Manufacturing Process of Metanilic Acid

This report comprises a thorough value chain evaluation for Metanilic Acid manufacturing and consists of an in-depth production cost analysis revolving around industrial Metanilic Acid manufacturing.

• Production from m-Nitrobenzene Sulfonic Acid, Iron Metal, and Hydrochloric Acid: The industrial manufacturing process of Metanilic Acid involves a chemical reduction reaction. The major feedstock for this process includes: m-nitrobenzene sulfonic acid (mainly as its sodium salt), iron metal (in powdered or granular form), and hydrochloric acid (HCl).

The process is initiated by charging m-nitrobenzene sulfonic acid, iron metal, and hydrochloric acid into a reaction vessel, usually an agitated reactor designed to handle acidic conditions. The hydrochloric acid facilitates the reduction of the nitro group (−NO2) to an amino group (−NH2). The iron metal reacts with the nitrobenzene sulfonic acid in the acidic medium.

The reaction is carried out under controlled temperature conditions. As the reaction proceeds, the m-nitrobenzene sulfonic acid is effectively converted to Metanilic Acid. During the reaction, iron is oxidised to iron salts (e.g., ferrous chloride) and eventually precipitates as iron hydroxides or oxides, which are solid by-products. After the reduction is complete, the reaction mixture is filtered to separate the Metanilic Acid product from the insoluble iron sludge. The crude Metanilic Acid is then purified through washing steps to remove residual impurities and salts, followed by drying to obtain the final Metanilic Acid powder.
 

Properties of Metanilic Acid

• Chemical Formula: C6H7NO3S
• Appearance: It appears as a white to beige crystalline powder.
• Melting Point: Above 300 degree Celsius (decomposes at this temperature).
• Solubility: It is slightly soluble in water (less than 1 mg/mL at 22 degree Celsius).
• Solubility in Organic Solvents: It is generally insoluble in most common organic solvents.
• Density: 1.69 g/cm³
• Chemical Structure: It consists of aromatic sulfonic acid with a benzene ring, an amino group (−NH2), and a sulfonic acid group (−SO3H) in the meta (1,3) positions.
• Acidic/Basic Nature: The sulfonic acid group is strongly acidic, and the amino group is weakly basic.
• Zwitterionic Nature: It can exist as an internal salt with a positively charged ammonium group and a negatively charged sulfonate group.
• Reactivity:
  • Can undergo reactions of aromatic amines (e.g., diazotisation, acylation)
  • Can also undergo reactions of sulfonic acids (e.g., salt formation)
• Stability: It remains relatively stable under normal storage conditions.
• Comparison to Isomers: Differentiates from its ortho and para-isomers (Orthanilic Acid and Sulfanilic Acid) due to its meta-substitution pattern, influencing its reactivity and applications.

Metanilic Acid 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 Metanilic Acid manufacturing plant report also covers the leading technology providers that help you plan a robust plan of action related to Metanilic Acid manufacturing plant and its production process, and also by helping you with an in-depth supplier database. This report provides exclusive insights into the best manufacturing practices for Metanilic Acid 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 Metanilic Acid 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 optimise supply chain operations, manage risks effectively, and achieve superior market positioning for Metanilic Acid.
 

Key Insights and Report Highlights

Key Questions Covered in our Metanilic Acid Manufacturing Plant Report

• How can the cost of producing Metanilic Acid be minimised, cash costs reduced, and manufacturing expenses managed efficiently to maximise overall efficiency?
• What is the estimated Metanilic Acid manufacturing plant cost?
• What are the initial investment and capital expenditure requirements for setting up a Metanilic Acid manufacturing plant, and how do these investments affect economic feasibility and ROI?
• How do we select and integrate technology providers to optimise the production process of Metanilic Acid, 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 Metanilic Acid manufacturing?
• How do market price fluctuations impact the profitability and cost per metric ton (USD/MT) for Metanilic Acid, and what pricing strategy adjustments are necessary?
• What are the lifecycle costs and break-even points for Metanilic Acid manufacturing, and which production efficiency metrics are critical for success?
• What strategies are in place to optimise the supply chain and manage inventory, ensuring regulatory compliance and minimising energy consumption costs?
• How can labour efficiency be optimised, and what measures are in place to enhance quality control and minimise 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, modernisation, and protecting intellectual property in Metanilic Acid manufacturing?
• What types of insurance are required, and what are the comprehensive risk mitigation costs for Metanilic Acid manufacturing?