ETHYL METHACRYLATE
[EIRI/EDPR/1474] J.C. 255
INTRODUCTION
Ethyl Methacrylate (EMA) is a key intermediate chemical, due to its ability to undergo polymerization and copolymerization. Polyacrylates, a family of clear and relatively durable thermoplastics are the major source for the consumption of EMA. At the end of 2008, there were almost 50 ethyl methacrylate manufacturing plants globally (some uncertainty exists over the precise number of plants in China where the very small localized plants are scattered over a wide geography) with plant sizes ranging from 1500 to 360000 metric tons per year (3.3 to 794 million pounds EMA per year). EMA can be commercially manufactured by a number of routes.
The conventional EMA process centers on the reaction of hydrogen cyanide (HCN) and acetone to give acetone cyanohydrin. The cyanohydrin then undergoes acid assisted hydrolysis and esterification with methanol to give ethyl methacrylate. This process (known as the ACH route) whilst quite economical if a producer has access to a low cost source of HCN, creates large amounts of ammonium bisulfate byproduct. This byproduct disposal issue and the handling of the highly toxic HCN, has prompted a great deal of research over the years aimed at developing newer cleaner and more cost effective process technologies for making EMA.
A number of alternative routes have been commercialized over the last two decades and more are claimed to be close to commercialization. These new routes range from using new feedstocks, such as isobutylene, ethylene, or even methylacetylene to developing techniques for recycling the HCN and/or the ammonium bisulfate. The Figure below summarizes the major chemistries and routes to EMA.
Ethyl methacrylate (EMA), the most important ester of methacrylic acid (MAA), is a key intermediate chemical. It can be homo- and copolymerised to produce acrylic resins with good strength, transparency and with excellent weather resistance.
COST ESTIMATION
Plant Capacity 33.34 MT/Day
Land & Building (15000 sq.mt.) Rs. 16.97 Cr
Plant & Machinery Rs. 5.75 Cr
Working Capital for 2 Months Rs. 49.31 Cr
Total Capital Investment Rs. 72.62 Cr
Rate of Return 58%
Break Even Point 24%
CONTENTS
INTRODUCTION
APPLICATIONS
MARKET SURVEY
METHODS OF PRODUCTION
FLOW SHEET
OTHER PROCESS
ENERGY BALANCE STUDY OF ETHYL METHACRYLATE
PRESENT MANUFACTURERS/SUPPLIERS OF ETHYL METHACRYLATE
SUPPLIERS OF PLANT AND MACHINERY
MANUFACTURERS/SUPPLIERS OF RAW MATERIALS
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)