Report Icc Prev 037 B Prem Usa

COMMODITY PRODUCTION COSTS
VOLUME 37
PHTHALIC ANHYDRIDE
ISSUE B
PHTHALIC ANHYDRIDE
PRODUCTION FROM
NAPHTHALENE
PREMIUM EDITION | USA
REPORT-ICC-PREV-037-B-PREM-USA
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How to cite this report: Intratec. 2024. Phthalic Anhydride Production from Naphthalene, Report
ICC-PREV-037-B-PREM-USA. In: Intratec Commodity Production Costs, Series XXXX. Volume 37
(Phthalic Anhydride). Issue B. Premium Edition. Rev 0.
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Abstract
This report presents Phthalic Anhydride manufacturing cost analysis of Phthalic Anhydride
production from naphthalene. The process examined is similar to the one developed by Badger. In
this process, naphthalene is oxidized by air in a fluidized bed reactor, yielding Phthalic Anhydride
product.
This report examines Phthalic Anhydride plant capital costs and the continuing operating costs
associated with the plant. The analysis assumes a plant based in the United States with a capacity
of 100.00 kt of Phthalic Anhydride per year and includes:
* Phthalic Anhydride plant capital cost details, including ISBL, OSBL and Contingency; owner's
cost; working capital; and costs incurred during industrial plant commissioning and start-up.
* Operating cost, broken down by variable costs (raw materials, utilities); fixed costs
(maintenance, operating labor, plant overhead, property taxes and insurance); and depreciation.
* Raw materials consumption, products generation, and labor requirements.
* Phthalic Anhydride production process information including block flow diagram (BFD), process
flow diagram (PFD) and description of industrial site installations.
Keywords: Unsaturated Polyester, UPR, Phthalic Acid, Fluidized Bed Reactor, Sherwin-Williams,
Badger
This is a preview, for full version visit: www.intratec.us/icc/037-B

Rev.0 i Premium Edition | USA
Revision Control
The following pages present a history of revisions and main changes made in the last updates of
the report “Phthalic Anhydride Production from Naphthalene.” The changes in each revision are
classified according to the types presented below:
* Fix: errors correction in a released report (e.g., typos, wrong descriptions/economic figures).
* Update: changes made by the Intratec team in the release of a new Series of reports (e.g.,
change of a technical parameter published in a more recent patent).
* Improvement: structural changes common to all Intratec Commodity Costs of Production

reports aiming to improve the accuracy of presented estimates or reader’s comprehension of
reports.
Report Revision History – Series XXXX
Rev. 0 Original

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Report Changes History – Previous Series
The list below presents the main changes made in the “Phthalic Anhydride Production from
Naphthalene” report released in previous Series.
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Preamble
Understanding Intratec Commodity Production Costs
Reports Organization
Intratec Commodity Production Costs is a set of best-in-class professional reports that can be
understood as an encyclopedia approaching plant capital and operating costs of commodities’
manufacturing processes. The Intratec Commodity Production Costs reports are organized in a
particular fashion, as shown in the diagram presented on the next page. The diagram shows that
the reports are organized in Quarterly Series according to the period of the economic analysis
presented. Every new quarter Intratec reviews the entire Series – new reports are developed, and
existing reports are updated. After the release of a new Series, the reports from previous Series
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The reports Series are divided into Volumes, with each Volume focusing on processes for
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each one targeting a specific industrial process to produce the respective commodity.
Each report is identified by a unique code, containing the information related to the Series, Volume,
Issue, Edition, and Location used as basis in the economic analysis. An example of code is
presented below.

Rev.0 iv Premium Edition | USA
Rev.0 v Premium Edition | USA
Editions Available
Aiming to attend customers with a wide range of needs, each Issue is offered within three different
Editions with increasing levels of depth, as detailed below.
* Compact Edition. This Edition describes the industrial plant, including main process units and
site infrastructure, and presents an independent economic analysis through summarized
figures. It is perfect for those looking for a brief overview of the process, and an objective
understanding of its economics.
* Detailed Edition. This Edition includes, besides all the content from the Compact Edition,
additional assumptions and further details related to the economic analysis. This Edition is
suggested for the readers interested in a more comprehensive analysis and concerned in
understanding each assumption used in the development of the Issue.
* Premium Edition. This is the most popular and detailed Edition offered for a given Issue. It
includes everything from the Detailed Edition plus additional economic and technical
information about the process, which enables readers to go deeper in their analysis. This
version is an excellent starting point for readers interested in checking different scenarios and
developing more in-depth studies.
For more information about the content of each Edition, the reader is referred to the Table of
Contents of each report.
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Rev.0 vi Premium Edition | USA
Companion Reports
Intratec also offers, as an add-on for the Premium Edition, companion reports with economic data
for the manufacturing process assuming other plant locations. More specifically, each companion
report has a detailed economic analysis with the same structure presented in the main report,
considering a plant in a different country.
Interested in Analysis in Other Countries?
The countries covered by the Commodity Costs of Production reports are: United States,
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About This Report
Identification
This report, “Report ICC-PREV-037-B-PREM-USA,” corresponds to the Issue B of a set of reports
which is part of Volume 37, released in the Series XXXX. More specifically, this report refers to:
Item Code Description
Product ICC Intratec Commodity Production Costs
Series XXXX Quarter (XX) and year (XXXX) used as basis for the economic
analysis
Volume 37 Phthalic Anhydride
Issue B Phthalic Anhydride Production from Naphthalene
Edition PREM Corresponds to the Premium Edition of the report
Country USA The economic analysis presented in this report is based on a plant
located in the United States

Rev.0 vii Premium Edition | USA
How to Use
The main purpose of this report is to assist readers in conducting a preliminary economic
evaluation of the industrial process presented. It serves as a valuable tool for studies such as
screening investment options, evaluating emerging processes, assessing economic feasibility, cost
estimation double-checking, and more.
Readers should keep in mind the limitations of this report, as both the technical data and economic
assessment are subject to certain constraints.
Technical Data. The preliminary design of the process is based on fast techniques that rely on
reduced design efforts. The goal of such preliminary design is exclusively to represent the process
in sufficient detail for supporting capital and operating costs estimation within the accuracy
expected: class 4 budgetary estimates. Therefore, the technical data presented must not be
confused with an actual conceptual process design and must not be used as such.
Economic Assessment. The economic assessment presented in this report, developed for the
period XXXX, assumes the construction of an industrial facility based in the United States. This
means that capital and operating costs estimates presented are based on several general
assumptions (e.g., average market figures for raw materials, chemicals and utilities prices, labor
costs, taxes, and duties), believed to suitably portray local conditions for the period of analysis
informed, on a country-level basis. Accordingly, the economic assessment provided in this report
is not meant to fit any specific industrial venture, which would involve a wealth of specific data and
assumptions not herein considered.
Finally, it is important to highlight mistakes to avoid when using Intratec Commodity Production
Costs reports:
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* Intratec reports are not consulting services, though users are free to use the information in
conjunction with their own data or hire consulting firms for specialized analyses.

Rev.0 viii Premium Edition | USA
Table of Contents
Abstract i
Revision Control ii
Preamble iv
Table of Contents ix
List of Figures xiii
List of Tables xv
Acronyms & Abbreviations xvii
Chapters
Executive Summary 1.1
About Phthalic Anhydride 1.1
Phthalic Anhydride Production Process 1.2
Economic Analysis 1.3
About Phthalic Anhydride 2.1
Commercial Forms & Applications 2.2
Phthalic Anhydride Production Routes 2.3
Process Overview 3.1
Technology Maturity Assessment 3.1
Product(s) Description 3.3
Inputs Description 3.3

Rev.0 ix Premium Edition | USA
Industrial Site Configuration 4.1
Process Unit 5.1
Block Flow Diagram 5.2
Description 5.4
Site Infrastructure 6.1
Assumptions 6.1
Description 6.2
Process Consumptions & Labor Requirements 7.1
Key Input & Output Figures 7.1
Labor Requirements 7.2
Capital Costs Summary - United States 8.1
Assumptions 8.2
Total Capital Investment 8.3
Operating Costs Summary - United States 9.1
Assumptions 9.2
Operating Variable Costs 9.3
Total Operating Cost 9.3
Product Value Summary - United States 10.1
Production Costs Summary - United States 11.1
Phthalic Anhydride Production Cost Datasheet 11.1
Economic Remarks 11.1
Analysis Methodology Summary 12.1
References 13.1
Methodology References 13.1
Analysis References 13.2

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Appendixes
Utilities Consumption Details * Only in Detailed & Premium Editions * A.1
Materials & Utilities Pricing Data - United States * Only in Detailed & Premium Editions * B.1
Analysis Pricing Basis B.1
Historical Prices B.1
Capital Costs Details - United States * Only in Detailed & Premium Editions * C.1
Fixed Capital Cost Details C.1
Working Capital Details C.3
Additional Capital Requirements Details C.4
Operating Costs Details - United States * Only in Detailed & Premium Editions * D.1
Utilities Costs Details D.1
Operating Fixed Costs Details D.2
Depreciation D.3
Product Value Details - United States * Only in Detailed & Premium Editions * E.1
Corporate Overhead Costs Details E.1
Return on Capital Employed (ROCE) E.1
Plant Cost Breakdowns * Only in Premium Edition * F.1
ISBL Construction Cost Breakdown F.1
OSBL Construction Cost Breakdown F.3
Plant Cost Breakdown per Discipline F.14
Plant Capacity Assessment - United States * Only in Premium Edition * G.1
Capital Cost for Different Capacities G.1
Operating Cost for Different Capacities G.3
Project Implementation & Construction Schedule * Only in Premium Edition * H.1
Process Flow Diagrams & Equipment List * Only in Premium Edition * I.1
About Intratec J.1
Our Business J.1

Rev.0 xi Premium Edition | USA
Our Products J.2
General Terms & Conditions K.1
Report Use Restrictions L.1

Rev.0 xii Premium Edition | USA
List of Figures
1.1 Process Schematic Diagram
2.1 Phthalic Anhydride Production Routes Diagram
4.1 Industrial Site Configuration
5.1 Block Flow Diagram - Manufacturing Process
6.1 Area 90 - Storage Installations
6.2 Area 91 - Utilities Facilities
6.3 Area 92 - Support & Auxiliary Buildings
8.1 Capital Investment Composition
8.2 Capital Investment Summary
9.1 Operating Costs Composition
9.2 Operating Costs Summary
10.1 Product Value Composition
10.2 Product Value Summary
12.1 Intratec Commodity Production Costs Reports Development Methodology
B.1 Historical Prices
C.1 Plant Cost Summary
D.1 Cost Distribution of Utility Consumption
F.1 Process Unit (ISBL) Construction Cost by Functional Unit
F.2 Site Infrastructure (OSBL) Construction Cost by Area
F.3 Storage Installations Construction Cost per Piece of Equipment
F.4 Utilities Facilities Construction Cost per Piece of Equipment

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F.5 Support & Auxiliary Buildings Construction Cost per Piece of Equipment
F.6 Plant Construction Cost Summary
F.7 Direct Construction Costs by Discipline
F.8 Indirect Costs Summary
G.1 Capital Investment Versus Plant Capacity
G.2 Operating Cost Versus Plant Capacity
H.1 Implementation & Construction Schedule
I.1 Convention for Process Equipment Tags
I.2 Symbols for Lines
I.3 Equipment Symbols - Reactors & Vessels
I.4 Equipment Symbols - Heat Exchangers
I.5 Equipment Symbols - Compressors & Pumps
I.6 Equipment Symbols - Columns
I.7 Equipment Symbols - Solids Processing
I.8 Process Flow Diagram

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List of Tables
1.1 Phthalic Anhydride Production Cost Summary
3.1 Process Technology Maturity Scale
7.1 Raw Materials Consumption
7.2 Products Generation
7.3 Labor Requirements
8.1 Capital Investment Summary
9.1 Operating Variable Costs
9.2 Operating Cost Summary
10.1 Product Value Composition
11.1 Phthalic Anhydride Production Cost Datasheet
12.1 Production Cost Datasheet Template
A.1 Net Utility Consumption Rates (per metric ton of Phthalic Anhydride)
A.2 Net Utility Generation Rates (per metric ton of Phthalic Anhydride)
B.1 Materials & Utilities Prices (United States, XXXX)
C.1 Plant Cost Estimate Accuracy Range (USD Million)
C.2 Owner's Cost Details
C.3 Fixed Capital
C.4 Working Capital Details
C.5 Additional Capital Requirements Details
D.1 Net Utilities Details
D.2 Operating Fixed Costs Details

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E.1 Corporate Overhead Costs Details
F.1 Process Unit (ISBL) Construction Cost by Functional Unit
F.2 Area 90 - Storage Installations: Scope Description
F.3 Area 91 - Utilities Facilities: Scope Description
F.4 Area 92 - Support & Auxiliary Buildings: Scope Description
F.5 Site Infrastructure (OSBL) Construction Cost by Piece of Equipment
F.6 Plant Construction Cost by Discipline
G.1 Capital Investment Analysis for Different Capacities (MM USD)
G.2 Operating Cost & Product Value Analysis for Different Capacities (USD/mt)
H.1 Project Phases Schedule
I.1 Diagram Legend - Utilities
I.2 Diagram Legend - Equipment Type

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Acronyms & Abbreviations
AACE Association for the Advancement of Cost Engineering
BEQ bare equipment
BFD block flow diagram
Btu British thermal unit
CAPEX capital expenditures
CW circulating cooling water
EPC engineering procurement and construction
FEED front-end engineering design
ft feet
G&A general and administrative
HAZOP hazard and operability study
HP high pressure
IC index Intratec plant construction cost index
ISBL inside battery limits
IT information technology
kWh kilowatt-hour
LP low pressure
m3 cubic meter
MM million
MP medium pressure

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mt metric ton
NASA National Aeronautics and Space Administration
Nm3 normal cubic meter
OC owner’s cost
Op. operator
OPEX operational expenditures
OSBL outside battery limits
PFD process flow diagram
R&D research and development
RF refrigeration fluid
ROCE return on capital employed
ST steam
Sup. supervisor
t ton
TFC total fixed capital
TPC total process capital
TRL technology readiness level
wt weight
yr year

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Chapter 1
Executive Summary
About Phthalic Anhydride
Phthalic Anhydride (a.k.a. PHTAN) is the anhydride of phthalic acid. It was the first anhydride to be
used commercially. It appears as a colorless or white solid in the form of needles or platelets and
it has a characteristic odor, being toxic if inhaled. When mixed with water, it forms a corrosive
solution. It is mainly used to produce plasticizers.
Phthalic Anhydride must be stored separated from combustible substances, strong oxidants,
reducing substances, strong acids, and bases. It should be stored in a cool and ventilated area out
of direct sunlight and away from ignition sources and heat. Shipment of Phthalic Anhydride is
made preferably in the molten form of the product. Insulated and heated tanks are used, as are
insulated rail tank cars and tank trucks. Rail tank cars can hold about 84 t, and trucks about 20 t.
The molten form can be handled and pumped in bulk form, and as a result, is priced lower than the
solid. Solid Phthalic Anhydride is available as a flake in 1 t and 0.5 t super sacks, and 22.7 kg
multiwall bags.
Phthalic Anhydride is mainly used as an epoxy resin curing agent and vulcanization retarder. It can
also be used as an intermediate in chemical resins, dyes, and pigment production.

Rev.0 1.1 Premium Edition | USA
Phthalic Anhydride Production Process
The present analysis approaches Phthalic Anhydride production from naphthalene.
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Figure 1.1 Process Schematic Diagram

Economic Analysis
Table 1.1 provides a summary of the Phthalic Anhydride production cost related to the process
described in the report, based on a 100.00 mt/yr plant. Also, it presents some remarks about the
key aspects surrounding the economic analysis performed.
Table 1.1 Phthalic Anhydride Production Cost Summary
Phthalic Anhydride Production from Naphthalene

Plant location United States Capital investment summary MM USD
Period of analysis XXXX (IC Index: XXX XXX) Fixed capital XXX
Nominal capacity (mt/yr) 100.00 Working capital XXX
Operating rate (h/yr) XXX XXX (XXX XXX%) Additional capital XXX
Annual production (mt/yr) XXX XXX Total capital investment XXX
Description USD/mt MM USD/yr %

Net raw materials cost XXX XXX XX
Net utilities cost XXX XXX XX
Operating variable costs XXX XXX XX
Operating fixed costs XXX XXX XX
Operating cash cost XXX XXX XX
Depreciation XXX XXX XX
Total operating cost XXX XXX XX
Corporate overhead XXX XXX XX
ROCE XXX XXX XX
Product value XXX XX
Table 1.1 shows the impact of variable costs in the product value — it represents approximately XX
% of the product value. Regarding the capital investment it is worth mentioning that, in order to
fulfill the infrastructure requirements assumed in the present analysis, OSBL investment represents
about XX% of the Phthalic Anhydride plant cost.

Chapter 2
About Phthalic Anhydride
Phthalic Anhydride (a.k.a. PHTAN) is the anhydride of phthalic acid. It was the first anhydride to be
used commercially. It appears as a colorless or white solid in the form of needles or platelets and
it has a characteristic odor, being toxic if inhaled. When mixed with water, it forms a corrosive
solution. It is mainly used to produce plasticizers.
Phthalic Anhydride must be stored separated from combustible substances, strong oxidants,
reducing substances, strong acids, and bases. It should be stored in a cool and ventilated area out
of direct sunlight and away from ignition sources and heat. Shipment of Phthalic Anhydride is
made preferably in the molten form of the product. Insulated and heated tanks are used, as are
insulated rail tank cars and tank trucks. Rail tank cars can hold about 84 t, and trucks about 20 t.
The molten form can be handled and pumped in bulk form, and as a result, is priced lower than the
solid. Solid Phthalic Anhydride is available as a flake in 1 t and 0.5 t super sacks, and 22.7 kg
multiwall bags.

Commercial Forms & Applications
The uses and applications of Phthalic Anhydride may vary according to the product grade. The
main forms of Phthalic Anhydride are: technical grade (5 to 8% moisture) and pure (99.8%
minimum purity).
Phthalic Anhydride is mainly used as an epoxy resin curing agent and vulcanization retarder. It can
also be used as an intermediate in chemical resins, dyes, and pigment production.
Phthalic Anhydride can be used in the manufacture of other products, including dioctyl phthalate;
phenolphthalein; unsaturated polyester resin; o-benzoylbenzoic acid; phthalimide.



Phthalic Anhydride Production Routes

Figure 2.1 Phthalic Anhydride Production Routes Diagram

Fig. 2.1 comprises a diagram showing different Phthalic Anhydride production processes. This
report is part of the Intratec Commodity Production Costs reports, focused on Phthalic Anhydride
manufacturing processes.
Other Issues, shown in the diagram, are focused on other Phthalic Anhydride production
processes. Brief descriptions of some of such industrial processes are presented below.
Issue A
It illustrates the Phthalic Anhydride production from o-xylene. In this plant, o-xylene is submitted to
a vapor phase oxidation, yielding Phthalic Anhydride product. See reference:
* Intratec. XXXX. Phthalic Anhydride Production from o-Xylene (Conventional Process), Report
ICC-XXXX-37-A-PREM-USA. In: Intratec Commodity Production Costs, Series XXXX. Volume 37
(Phthalic Anhydride). Issue A. Premium Edition. Available at: www.intratec.us/icc/037-A.
Issue C
It illustrates the Phthalic Anhydride production from o-xylene. In this process, the fixed-bed
catalytic oxidation occurs with air/o-xylene weight ratio of 9.5:1, yielding Phthalic Anhydride
product. See reference:
* Intratec. XXXX. Phthalic Anhydride Production from o-Xylene (Low Air Ratio Process), Report
ICC-XXXX-37-C-PREM-USA. In: Intratec Commodity Production Costs, Series XXXX. Volume 37
(Phthalic Anhydride). Issue C. Premium Edition. Available at: www.intratec.us/icc/037-C.
Interested in a Different Commodity Production Costs Report?

It is worth mentioning that Intratec is always working to increase its portfolio. However, if any
customer is interested in a process not yet examined in an off-the-shelf report, Intratec can
also develop a Commodity Production Costs report on-demand. Such tailored reports can be
easily ordered online at: https://intrat.ec/custom-icc.

Chapter 3
Process Overview
This chapter presents an overview of Phthalic Anhydride production from naphthalene.
More specifically, the current chapter approaches technical aspects of the Phthalic Anhydride
production process examined including technology maturity assessment and description of the
products generated and the process inputs.
Technology Maturity Assessment
The process technology under study was categorized according to its maturity. The technical
maturity, while a measure of performance, reliability and operating experience associated with the
technology being assessed, serves as an important input in the definition of assumptions that have
a relevant impact on process economics (e.g., process contingency, project contingency, costs
related to start-up inefficiencies and R&D, etc.).
The process technology maturity is defined by the Intratec team through a method adapted from
the so-called Technology Readiness Level (TRL) method, developed by NASA, and nowadays used
in a broad range of sectors/industries. There are nine TRLs, which describe the maturity of a
technology, from basic technology research to system testing, launch and operations.
Originally intended to support decision-making over research and development activity, the nine
technology readiness levels were divided into five major classes to portray the maturity level of
chemical process technologies, from “concept” to “established technology.” Table 3.1 describes
such five classes according to which the Intratec team classifies technologies being studied, as
well as the TRLs included within each class.

Table 3.1 Process Technology Maturity Scale
Technology Status Description Scale TRL

Established (Outdated) * Existing plants being shut down Commercial (at least 1 plant) -
* No longer adopted in new plants

* Obsolete technology
Established (In Use) * 2+ commercial plants Commercial (2+ plants) 9

* Proven technology (successful
operations)
Emerging * 1 commercial plant Commercial (1 plant) 7-8

* Basic data for commercial plant
* Performance validation
* Demonstration plant
Demonstration
* Prototype near or at planned
operation system
Embryonic * Pilot-scale demonstration Pilot 4-6

* Engineering-scale models /
prototypes
* Basic data for scale-up
* “Proof-of-Concept” validation
* Bench-scale demonstration
* Lab-scale technology definition Bench 2-3
* Process modeling Lab

* Analytical studies
* Active R&D
Conceptual * Unproven idea / proposal Concept 1

* No analysis or testing Idea
* Paper concept / studies


Product(s) Description



Inputs Description
Raw Material(s)


Utilities



Process Highlights





Chapter 4
Industrial Site Configuration
This chapter presents the industrial site configuration for the Phthalic Anhydride production
process examined. In short, the information presented in this chapter is based on commonly
utilized concepts related to the type of installations found within a typical industrial site. These
concepts include:
* Process unit. Also known as inside battery units, these installations comprise all main units of
the site required to modify the input stream and obtain the target output. These units are located
Inside the Battery Limits (ISBL).
* Infrastructure. Also known as outside battery units or offsite facilities, these installations do
not directly enter into the modification of the process input stream. They are support buildings,
auxiliary units used for providing and distributing utilities and storage facilities. These units are
located Outside the Battery Limits (OSBL).
In order to make a better distinction between these types of installation, a diagram is presented in
Figure 4.1. The diagram also provides an insightful overview of the industrial site as whole, and
helps to clarify which raw materials and utilities are supplied to the process unit and which
products and utilities are generated.

Figure 4.1 Industrial Site Configuration
Chapter 5
Process Unit
This chapter presents the process unit associated with the Phthalic Anhydride production from
naphthalene. The process examined is similar to the one developed by Badger.
Basically, the process unit is the core of an industrial site. Comprising the site’s battery limits
(ISBL), it may be complex and involve several pieces of equipment. In this context, to facilitate the
understanding, the process unit related to the Phthalic Anhydride manufacturing process under
analysis is presented in the next pages through the use of a block flow diagram followed by a
comprehensive description.
It is important to mention that some aspects of the Phthalic Anhydride production process
examined are either industrial secrets, not published in patents, or have changed, but were not
reported in the literature at the time this report was developed. That being the case, the design
herein presented is partially based on Intratec process synthesis knowledge such that there may
be some differences between the industrial process actually employed and the Phthalic Anhydride
manufacturing process described in this study. Nevertheless, the design presented suitably
represents the technology examined in sufficient detail to estimate the economics of the
technology within the degree of accuracy expected from conceptual evaluations.

Block Flow Diagram
In general, block flow diagrams consist of a series of blocks, representing unit operations or
groups of equipment, connected by input and output streams. In fact, there are no strict standards
according to which such diagrams are made.
To facilitate the presentation of the process unit under analysis, Intratec developed block flow
diagrams according to some standards. The process areas represented correspond to a
“functional unit.” Basically, a “functional unit” is a significant step in the process in which a
particular physico-chemical operation (i.e., distillation, reaction, evaporation) occurs. According to
this definition, a given functional unit is not associated with a single piece of equipment, but rather
with a group of equipment and ancillaries required to perform a particular operation.
The blocks representing process areas also show key technical parameters related to these areas,
including: the highest operating temperature and pressure, representative material of construction,
and other parameters.
As to the process streams represented, there is an indication of their phase. Also, such streams
may provide a global material balance of the process, normalized by the mass flow rate of the
product considered in the analysis. In other words, the number near each stream represents the
ratio between its mass flow rate and the output flow rate of the product under analysis.
It is worth noting that areas having no significant impact on the economics of the process may not
be included in the diagram. Similarly, some streams may also not be represented. Nevertheless,
the diagram presented is still extremely useful in providing readers with an overall understanding
of the process studied.
The following block flow diagram illustrates the functional units related to the process under
analysis.
Further Details
For more information on how the process examined was divided into functional units, the
reader is referred to https://intrat.ec/m?f=/icc-methodology.

Figure 5.1 Block Flow Diagram — Phthalic Anhydride Manufacturing Process
Further Details
For a more detailed diagram presenting pieces of equipment and more process streams, the
reader is referred to “Appendix I. Process Flow Diagram & Equipment List.”
Description
The Phthalic Anhydride production process under analysis is briefly described below. For clarity,
the description was divided according to the process areas indicated in the block flow diagram.

* XX - XXXXXXXXX

* XX - XXXXXXXXX

* XX - XXXXXXXXX

* XX - XXXXXXXXX

* XX - XXXXXXXXX

* XX - XXXXXXXXX


* XX - XXXXXXXXX


Chapter 6
Site Infrastructure
This chapter describes the infrastructure requirements associated with the Phthalic Anhydride
production process examined. Basically, infrastructure requirements comprise the offsite facilities,
or the units located Outside the Battery Limits (OSBL). The OSBL usually have a significant impact
on the capital cost estimates associated with any new industry venture. This impact is largely
dictated by, among other things: specific conditions where the industrial site will be erected; the
level of integration the new site will have with nearby facilities or industrial complexes; and
assurance and promptness in the supply of chemicals.
Assumptions
The infrastructure requirements of the industrial site examined were defined according to the
assumptions listed below.







Note
According to the literature focused on the economic analysis of processes, the costs
associated with waste treatment typically range from 0.5% to 5% of plant cost per year (See
references M14, M15). However, since such costs may significantly vary from process to
process and according to plant location, Intratec recommends a specific study for more
accurate estimates.
Description
The offsite facilities were divided into areas according to their type/function. These areas are
listed in the following pages, as well as a description about the major equipment, systems and
facilities included in each of them.

* Area 90 – Storage Installations
Figure 6.1 Area 90 – Storage Installations


* Area 91 – Utilities Facilities
Figure 6.2 Area 91 – Utilities Facilities


* Area 92 – Support & Auxiliary Buildings
Figure 6.3 Area 92 – Support & Auxiliary Buildings


Chapter 7
Process Consumptions & Labor Requirements
This chapter presents the process requirements to operate an industrial site of the Phthalic
Anhydride production process examined. More specifically, the next pages provide key process
indicators and the operators required to run the process equipment of the Phthalic Anhydride
manufacturing process examined (in accordance with the block flow diagram and the global
material balance previously presented).
Key Input & Output Figures
The following tables show key process indicators of the technology examined. In other words,
these indicators reflect the raw materials consumption in Table 7.1 rates per metric ton of Phthalic
Anhydride.
Table 7.1 Raw Materials Consumption
Raw Material Quantity per metric ton of Product Unit

XXXXXXXXX XXX XXX
XXXXXXXXX XXX XXX
It should be noted that estimation of raw material requirements in the conceptual design phase is
usually reasonably accurate, but tends to be somewhat understated compared to real operations.
Losses from vessel vents, unscheduled equipment, inerting systems, physical property
inaccuracies, startup, shutdown, and other process operations not typically addressed in this
phase may increase raw materials consumption.

Further Details
For detailed figures regarding utilities consumption, reader is referred to “Appendix A. Utilities
Consumption Details.”
Labor Requirements
Table 7.2 presents the number of operators per shift required to run the equipment of the process
examined, as well as the personnel per shift required to directly supervise the operating labor.
Table 7.2 Labor Requirements
Personnel Workers per Shift

Operators XX
Supervisors XX

Chapter 8
Capital Costs Summary - United States
This chapter presents Phthalic Anhydride plant capital costs associated with Phthalic Anhydride
production from naphthalene, from design to industrial plant startup.
The costs that comprise the total Phthalic Anhydride plant capital costs are grouped under three
major costs:
* Fixed capital. Depreciable capital invested in the construction of the industrial plant and
making it operational. It comprises the Phthalic Anhydride plant cost and owner’s cost,
expenses required to make the plant operational (i.e., initial catalyst load in reactors, prepaid
royalties, and miscellaneous costs).
* Working capital. Funds for getting the plant into operation and meeting subsequent
obligations. It includes raw materials inventory, products inventory, in-process inventory,
supplies and stores, accounts receivable and accounts payable.
* Additional capital requirements. One-time expenses related to bringing a process on stream

during plant start-up. These expenses may be related to employee training, initial
commercialization costs, operating inefficiencies, and unscheduled plant modifications.
Figure 8.1 illustrates the composition of total capital investment.
Further Details
For more information about how the capital costs were estimated, the reader is referred to
https://intrat.ec/m?f=/icc-methodology.

ADDITIONAL CAPITAL
TOTAL CAPITAL INVESTMENT
WORKING CAPITAL
OWNER'S COST FIXED CAPITAL
PROJECT CONTINGENCY PLANT COST
PROCESS
OUTSIDE BATTERY LIMITS (OSBL) INVESTMENT CAPITAL
PROCESS CONTINGENCY
INSIDE BATTERY LIMITS (ISBL) INVESTMENT
Figure 8.1 Capital Investment Composition
Assumptions
The estimates included in this chapter are based on the following assumptions:
* Plant nominal capacity: 100.00 kt of Phthalic Anhydride per year
* Industrial plant location: United States
* Construction on a cleared, level site
* Period of analysis: XXXX
* IC Index-United States at the period of analysis: XXX XXX
Interested in Adjusting Construction Costs Over Time?

Intratec Plant Construction Cost Indexes (IC Indexes) are multipliers monthly published by
Intratec to scale capital costs from one time period to another. For more information, visit
https://intrat.ec/industry-economics-worldwide.

Total Capital Investment
Table 8.1 summarizes all major Phthalic Anhydride plant capital costs that comprise the total
capital investment, from the design and construction of an industrial site to plant startup.
Table 8.1 Capital Investment Summary
Component MM USD %
Plant cost XXX XX
Owner’s cost XXX XX
Total fixed capital XXX XX
Working capital XXX XX
Additional capital XXX XX
Total capital investment XXX XX
Figure 8.2 presents a graphical representation of the total capital investment breakdown.
Figure 8.2 Capital Investment Summary

Further Details
For the breakdown of fixed capital, working capital and additional capital, reader is referred to
“Appendix C. Capital Investment Details.”

Chapter 9
Operating Costs Summary - United States
This chapter presents ongoing costs required for Phthalic Anhydride production from naphthalene.
Also referred to as operational expenditures (OPEX), these encompass costs associated with the
plant operation and depreciation. In the current analysis, the operating cost was grouped under
three major costs:
* Operating variable costs. Costs directly proportional to the actual operating rate of the
industrial site. Such costs include raw materials and utilities (i.e., steam, electricity, fuel, and
refrigeration).
* Operating fixed costs. Operating costs directly tied to the plant capacity, but which do not
change with the operating level (i.e., operating labor, supervision labor, maintenance costs,
plant overhead).
* Depreciation. Refers to the decrease in value of industrial assets with passage of time.
It should be kept in mind that the sum of operating fixed costs and operating variable costs is
referred to as “cash cost.” The sum of cash cost with depreciation, in turn, is referred to as “total
operating cost.”
Figure 9.1, on the next page, illustrates the composition of total operating cost.
Further Details
For more information about how the operating cost components were estimated, the reader is
referred to https://intrat.ec/m?f=/icc-methodology.

DEPRECIATION TOTAL OPERATING COST
PROPERTY TAXES AND INSURANCE OPERATING CASH

PLANT OVERHEAD
FIXED COST COST
LABORATORY EXPENSES
OPERATING SUPPLIES
MAINTENANCE MATERIAL
PAYROLL CHARGES
MAINTENANCE LABOR
SUVERVISION LABOR
OPERATING LABOR
OPERATING
NET UTILITIES COST VARIABLE
COST
GROSS RAW MATERIALS COST LESS BY-PRODUCTS CREDIT
Figure 9.1 Operating Costs Composition
Assumptions
The estimates included in this chapter are based on the following assumptions:
* Industrial plant location: United States
* Period of analysis: XXXX
* Plant nominal capacity: 100.00 metric ton of Phthalic Anhydride per year
* Plant operating rate (hours per year): XXX XXX
The plant operating rate assumed leads to an annual throughput of XXX XXX metric ton of Phthalic
Anhydride. It is important to mention that this rate does not represent any technological limitation;
rather, it is an assumption based on usual industrial operating rates.

Operating Variable Costs
Table 9.1 displays the operating variable costs.
Table 9.1 Operating Variable Costs
Component Quantity Price USD/mt MM USD/yr %
XXXXXXXXX XXX XXX XXX XXX XXX XX

XXXXXXXXX XXX XXX XXX XXX XXX XX
Gross raw materials cost XXX XXX XX
All costs presented in this table are derived from unit consumptions and pricing information.
Total Operating Cost
Table 9.2 summarizes all operating cost by presenting its major components.
Table 9.2 Operating Cost Summary
Component USD/mt MM USD/yr %

Operating fixed costs XXX XXX XXX
Figure 9.2 presents a graphical representation of the operating cost breakdown.

Figure 9.2 Operating Costs Summary
Further Details
For the breakdown of utilities cost, operating fixed costs and depreciation, the reader is
referred to “Appendix D. Operating Costs Details.”

Chapter 10
Product Value Summary - United States
This chapter presents the “Product Value,” a term commonly used wherein all costs associated
with the manufacture of a product are combined in order to provide a more consistent economic
analysis. It includes operating cost (operating variable costs, operating fixed costs, and
depreciation), as well as corporate overhead costs and an expected Return on Capital Employed
(ROCE). Figure 10.1 illustrates the composition of the product value.
PRODUCT VALUE
ROCE
CORPORATE OVERHEAD
TOTAL OPERATING COST

DEPRECIATION
OPERATING FIXED COST OPERATING CASH COST
OPERATING VARIABLE COST
Figure 10.1 Product Value Composition

It is important to mention that product value should not be confused with product price. The
product value should be seen as the minimum price for which the product could be sold, so that
the plant owner can get the expected ROCE.
Table 10.1 summarizes all costs that comprise the product value in the process examined.
Table 10.1 Product Value Composition
Component USD/mt MM USD/yr %

ROCE XXX XXX XX
Figure 10.2 shows the impact of each cost component on the product value.
Figure 10.2 Product Value Summary

Chapter 11
Production Costs Summary - United States
This chapter provides a summary of all Phthalic Anhydride production costs related to the process
described so far. Also, it presents some remarks about the key aspects surrounding the economic
analysis.
Phthalic Anhydride Production Cost Datasheet
Table 11.1 condenses the analysis developed in this report.
Economic Remarks
It should be noted that the risk taken into account in this analysis is limited to the technical risks
associated with the process uncertainties or inherent risks associated with the venture's industry
sector. Other venture risks, such as business environment, raw materials and product prices
variations, change in government policy, shall be evaluated case by case, and are not taken into
account here, since this is a general analysis.
It is also important to mention that product value must not be confused with product price. While
the product value is calculated based on operating cost and expected ROCE, the product price is
the actual value practiced in market transactions.

Table 11.1 Phthalic Anhydride Production Cost Datasheet
Phthalic Anhydride Production from Naphthalene

Plant location United States Capital investment summary MM USD
Period of analysis XXXX (IC Index: XXX XXX) Fixed capital XXX
Nominal capacity (mt/yr) 100.00 Working capital XXX
Operating rate (h/yr) XXX XXX (XXX XXX%) Additional capital XXX
Annual production (mt/yr) XXX XXX Total capital investment XXX
Description Quantity per mt Price USD/mt MM USD/yr %

XXXXXXXXX XXX XXX XXX/XXX XXX XXX XX
XXXXXXXXX XXX XXX XXX/XXX XXX XXX XX
Gross raw materials cost XXX XXX XX
ROCE XXX XXX XX
Further Details
For further clarification about the pricing assumptions used in this analysis, the reader is

Chapter 12
Analysis Methodology Summary
This chapter provides a brief summary of the methodology developed by Intratec for producing its
Production Cost Reports. For a more-in-depth comprehension, readers are encouraged to explore
the Intratec Commodity Production Costs – General Methodology Guide, which can be accessed at:
► https://intrat.ec/m?f=/icc-methodology
The Intratec Commodity Production Costs report is a critical tool for evaluating industrial
processes from a techno-economic perspective. Leveraging over a decade of experience in
commodities markets and process economics, Intratec has developed a robust and consistent
methodology to ensure reliable and comprehensive techno-economic evaluations.
A techno-economic assessment analyzes industrial processes from an economic viewpoint,

considering factors such as operating costs, capital investments, and process requirements. This
evaluation supports investment screening, process assessment, and the analysis of industrial
ventures' economic feasibility.
The primary goal of the report is to deliver best-in-class economic evaluations, summarized as
shown in Table 12.1, providing trustworthy estimates for informed decision-making. This approach
offers readers clear insights into the economic viability of process technologies in dynamic
markets.
To produce high-quality reports, Intratec conducts detailed research into raw materials, products,
and processes, including thorough technical analyses of Inside Battery Limits (ISBL) and Outside
Battery Limits (OSBL) areas. This analysis is grounded in an extensive bibliography of books,
patents, and academic papers.

Table 12.1 Production Cost Datasheet Template
Intratec Commodity Production Costs

Plant location (e.g., USA) Capital investment summary MM USD
Period of analysis (IC Index: ) Fixed capital
Nominal capacity (mt/yr) Working capital
Operating rate (h/yr) ( %) Additional capital
Annual production (mt/yr) Total capital investment
Description Quantity per product Price USD/mt MM USD/yr %

Raw material 1 mt USD/mt
Gross raw materials cost
By-product 1 mt USD/mt
By-product 2 mt USD/mt
By-product credits
Net raw materials cost
Cooling water m3 USD/m3
Demineralized water m3 USD/m3
Electricity kWh USD/kWh
Steam (HP) mt USD/mt
Utilities consumption
Fuel credit MMBtu USD/MMBtu
Steam (LP) mt USD/mt
Utilities generation
Net utilities cost
Operating variable costs
Operating fixed costs
Operating cash cost
Depreciation
Total operating cost
Corporate overhead
ROCE
Product value

Using this technical foundation, key process indicators, site configurations, and labor requirements
are defined. These inputs are then applied to calculate capital investment and operating costs.
Capital investment is categorized into fixed, working, and additional capital, while operating costs
are divided into variable costs, fixed costs, and depreciation.
Accuracy is paramount, and Intratec continuously gathers comprehensive data on commodity

prices, utilities, and labor costs for the specific country and period of the study. This data is
sourced from both public and private entities, including national statistics bureaus, government
agencies, international organizations, market exchanges, and producers.
For simplicity, all cost estimates are consolidated into a single item: the “Product Value.” This value
combines operating costs (variable, fixed, and depreciation), corporate overhead, and a return on
capital employed (ROCE), which reflects the capital investment.
All Intratec reports that approach industrial processes have a common structure, i.e., indexes,
tables, and charts share similar standards. This ensures that Intratec’s readers know upfront what
they will get and, more than that, will be able to compare technologies addressed in different
reports.
Our methodology is continuously tested and validated by manufacturers, R&D centers, EPC
companies, financial institutions, and government agencies that rely on our reports. Figure 12.1
illustrates the methodology used in this report.
Complementary Documents
In addition to the full analysis methodology (https://intrat.ec/m?f=/icc-methodology), Intratec
provides two other documents with complementary information to this report: “Glossary &
Abbreviations” and “Unit Conversion.”
The “Glossary & Abbreviations” document contains definitions of important commodity market
terms found in this report and our other products. Access it at: https://intrat.ec/glossary.
The “Unit Conversion” table presents unit conversion factors for several length, mass, energy
units, and more. Access it at: https://intrat.ec/unit-conversion.

Figure 12.1 Intratec Commodity Production Costs Reports Development Methodology

Chapter 13
References
Methodology References
Intratec has built its knowledge based on the most relevant text books, encyclopedias, and
technical papers related to the economic evaluation of industrial processes. Such expertise has
established a large foundation that enriches all Intratec reports, in a way that the reader can expect
the most trustworthy information.
The methodology references reflect this foundation of bibliographical data, used in the
development of all Intratec Commodity Production Costs reports, particularly in the elaboration of
the methodology employed, detailed in Chapter 12.
[M1] Acland, M., et al. 2012. Cost Estimation Handbook (2nd ed.). The Australasian Institute of
Mining and Metallurgy
[M2] Baasel, W. D.. 1989. Preliminary Chemical Engineering Plant Design (2nd ed.). Springer
[M3] Brennan, D.. 2020. Process Industry Economics (2nd ed.). Institution of Chemical
Engineers
[M4] Chauvel, A.; Fournier, G.; Raimbault, C.. 2003. Manual of Process Economic Evaluation (4th
ed.). Editions Technip
[M5] Couper J. R.. 2003. Process Engineering Economics (1st ed.). CRC Press
[M6] Gerrard, A. M.. 2000. Guide to Capital Cost Estimating (4th ed.). Institution of Chemical
Engineers
[M7] Humphreys. K. K.. 2004. Project and Cost Engineers’ Handbook (4th ed.). CRC Press
[M8] Humphreys K. K.; Wellman, P.. 1995. Basic Cost Engineering (3rd ed., Revised and
Expanded). CRC Press

[M9] Hydrocarbon Processing. 2005. Petrochemical Processes Handbook. Gulf Publishing
[M10] Lange, J. P.. 2001. Fuels and Chemicals Manufacturing - Guidelines for Understanding and
Minimizing the Production Costs. CatTech V.5 no 2. pp. 82-95
[M11] Marsden, R. S.; Craven, P. J.; Taylor, J. H.. 1982. A New Technique for Estimating Process
Energy Cost at The Predesign Stage. Transaction of the 7th International Cost Engineering
Congress
[M12] Matthews, L. M.. 1983. Estimating Manufacturing Costs A Practical Guide for Managers &
Estimators (1st ed.). McGraw-Hill Companies
[M13] Peters, M. S.; Timmerhaus, K. D.; West, R. E.. 2002. Plant Design and Economics for
Chemical Engineers (5th ed.). McGraw-Hill Education
[M14] Pike, R. W.. 2015. Essentials of Economic Decision Analysis for Chemical Engineering (1st
ed.). CreateSpace Independent Publishing Platform
[M15] Tedder, W. T.. 2005. Preliminary Chemical Process Design & Economics. Hickory Mountain
[M16] Towler, G., Sinnott, R. 2021. Chemical Engineering Design Principles, Practice and
Economics of Plant and Process Design (3rd ed.). Butterworth-Heinemann
[M17] Tsagkari, M., Couturier J., Dubois, J., and Kokossis, A.. 2015. Heuristics for Capital Cost
Estimation: A Case Study on Biorefinery Processes.
[M18] Turton, R.; Bailie, R. C.; Whiting, W. B.; Shaeiwitz, J. A.; Bhattacharyya, D.. 2012. Analysis,
Synthesis, and Design of Chemical Processes (4th ed.). Prentice Hall
[M19] Ulrich, G. D.; Vasudevan, P. T.. 2003. Chemical Engineering Process Design and
Economics: A Practical Guide (2nd ed.). CRC Press
Analysis References
The analysis references present the foundation of this Phthalic Anhydride production cost report,
providing information required to fully understand the industrial process addressed and to
formulate the assumptions considered. These references, presented below, may encompass
patents, encyclopedias, textbooks, academic or professional researches, technical papers and any
other non-confidential information publicly available, duly reviewed by Intratec’s team.
[A1] XXXXXXXXXX XXXXXXXXXX XXXXXXXXXX XXXXXXXXXX XXXXXXXXXX XXXXXXXXXX






Appendix A
Utilities Consumption Details
This appendix details the key utilities consumption indicators of the technology examined in the
report. In other words, these indicators reflect the net utilities consumption rates per metric ton of
Phthalic Anhydride produced presented in Table A.1.
Table A.1 Net Utility Consumption Rates (per metric ton of Phthalic Anhydride)
Utility Consumption per metric ton

XXXXXXXXX XXX XXX
XXXXXXXXX XXX XXX
XXXXXXXXX XXX XXX
XXXXXXXXX XXX XXX
It should be noted that estimation of utility requirements in the conceptual design phase is usually
fairly accurate, but tends to be somewhat low compared to real operations. Losses from vessel
vents, unscheduled equipment, inerting systems, physical property inaccuracies, startup, shutdown
and other process operations not typically addressed in this phase may increase utilities
consumption.

Rev.0 A.1 Premium Edition | USA
Appendix B
Material & Utilities Pricing Data - United States
This appendix presents details of the pricing data used in the economic analysis within this report.
Analysis Pricing Basis
The economic analysis presented is based on the prices seen in Table B.1.
Table B.1 Materials & Utilities Prices (United States, XXXX)
Description Price Unit Remark

Raw materials
XXX XXX USD/XXX XXX
XXX XXX USD/XXX XXX
Utilities
XXX XXX USD/XXX XXX
XXX XXX USD/XXX XXX
XXX XXX USD/XXX XXX
XXX XXX USD/XXX XXX
Historical Prices
The evolution of material costs over the past three years is depicted in the following pages.

Rev.0 B.1 Premium Edition | USA
Figure B.1 Historical Prices

Rev.0 B.2 Premium Edition | USA
Appendix C
Capital Costs Details - United States
This appendix details Phthalic Anhydride plant cost, working capital and additional capital,
discussed in “Chapter 8. Capital Costs Summary.”
Fixed Capital Cost Details
Fixed capital constitutes the fraction of the capital investment which is depreciable. It includes the
Phthalic Anhydride plant cost and owner's cost.
Plant Cost
The Phthalic Anhydride plant cost, i.e., the cost related to the construction of the industrial site
itself, is broken down into the components presented in Table C.1.
Table C.1 Plant Cost Estimate Accuracy Range (USD Million)
Component Estimate Lower Limit Upper Limit %

Inside battery limits (ISBL) XXX XXX XXX XX
Process contingency (XX% of ISBL) XXX XXX XXX XX
Outside battery limits (OSBL) XXX XXX XXX XX
Total process capital (TPC) XXX XXX XXX XX
Project contingency (XX% of TPC) XXX XXX XXX XX
Plant cost XXX XXX XXX XX
The lower and upper limits for the Phthalic Anhydride plant cost figures, according to the accuracy
range expected from conceptual evaluations presented in this report, are also presented in Table
C.1. The presented range is associated with a confidence level of 90%.

Rev.0 C.1 Premium Edition | USA
Figure C.1 summarizes all items that make up the plant cost.
Figure C.1 Plant Cost Summary
Further Details
For more information about the breakdowns for the Phthalic Anhydride plant capital cost, the
reader is referred to “Appendix F. Plant Cost Breakdowns.”
Owner's Cost
The owner's cost encompasses the expenses required to make the plant operational. Its
components are presented in Table C.2.

Table C.2 Owner's Cost Details
Component Assumption MM USD %

Prepaid royalties XX% of plant cost XXX XX
Miscellaneous costs XX% of plant cost XXX XX
Fixed Capital Summary

Table C.3 summarizes the fixed capital components that result in total fixed capital.
Table C.3 Fixed Capital
Component MM USD %
Plant cost XXX XX
Total fixed capital XXX XX
Further Details
For more information about each cost presented in this appendix, the reader is referred to
https://intrat.ec/m?f=/icc-methodology
Working Capital Details
Working capital, i.e., the funds for getting the plant into operation and meeting subsequent
obligations, is broken down in Table C.4.

Table C.4 Working Capital Details

Accounts receivable XX day(s) of total operating cost + corporate XXX
Accounts payable XX day(s) of operating cash cost + corporate XXX
Net accounts receivable XXX XX
Raw materials inventory XX day(s) of raw materials costs XXX XX
In-process inventory XX day(s) of operating cash cost + corporate XXX XX
Products inventory XX day(s) of total operating cost + corporate XXX XX
Supplies and stores XX% of annual operating labor & maintenance costs XXX XX
Cash on hand XX day(s) of operating cash cost + corporate XXX XX
Total working capital XXX XX
Additional Capital Requirements Details
Additional capital requirements are one-time expenses related to bringing a process on stream
during plant start-up. Table C.5 presents the breakdown of this cost with all its components.
Table C.5 Additional Capital Requirements Details

Operator training XX day(s) of operating + supervision labor costs XXX XX
Commercialization costs XX% of annual operating cash cost + corporate XXX XX
Start-up inefficiencies XX% of annual operating cash cost + corporate XXX XX
Unscheduled plant XX% of plant cost XXX XX
Start-up costs XXX XX
Land & site development XX% of plant cost XXX XX
Total additional capital XXX XX

Appendix D
Operating Costs Details - United States
This appendix details utilities cost, operating fixed cost and depreciation, discussed in “ Chapter 9.
Operating Costs.”
Utilities Cost Details
Utilities cost component encompasses costs related to a plant’s consumption of steam, electricity,
fuel, and refrigeration. Table D.1 summarizes net utility costs for this cost analysis.
Table D.1 Net Utilities Details
Utility Consumption Price USD/mt MM USD/yr %

XXXXXXXXX XXX XXX XXX USD/XXX XXX XXX XX
Net utility cost XXX XXX
Further Details
For more information about how the utilities cost components were estimated, the reader is
Figure D.1 illustrates the utilities with greatest impact on the total utility consumption.

Rev.0 D.1 Premium Edition | USA
Figure D.1 Cost Distribution of Utility Consumption
Operating Fixed Costs Details
Operating costs directly tied to the plant capacity, but which do not change with the operating level.
Table D.2 presents the breakdown of operating fixed cost.

Table D.2 Operating Fixed Costs Details
Component Assumption USD/mt MM USD/yr %

Operating labor XX operators; XXX USD/oper./h XXX XXX XX
Supervision labor XX supervisors; XXX USD/oper./h XXX XXX XX
Payroll charges related to operating and supervision labor XXX XXX XX
Maintenance labor XX% of plant cost per year XXX XXX XX
Maintenance materials XX% of plant cost per year XXX XXX XX
Operating supplies XX% of maintenance costs XXX XXX XX
Laboratory expenses XX% of operating labor costs XXX XXX XX
Plant overhead XX% of operating labor and maintenance XXX XXX XX
Property taxes & insurance XX% of fixed capital per year XXX XXX XX
Depreciation
In this study, the depreciation unit cost corresponds to XXX USD/mt of Phthalic
Anhydride produced. This calculation was based on the straight-line method and a project
economic life of 10 years for both the core production unit (ISBL assets) and owner's assets, and
20 years for the site infrastructure (OSBL assets).
Further Details
For more information about how operating fixed costs components and depreciation were
estimated, the reader is referred to https://intrat.ec/m?f=/icc-methodology.

Appendix E
Product Value Details - United States
This appendix details corporate overhead costs and the return on capital employed, both of which
make up the product value, presented in “Chapter 10. Product Value Analysis.”
Corporate Overhead Costs Details
Corporate overhead is associated with costs incurred by a company’s head office. Table E.1
presents a breakdown of corporate overhead costs.
Table E.1 Corporate Overhead Costs Details
Component Assumption USD/mt MM USD/yr %

Administration costs XX% of operating labor and maintenance XXX XXX XX
Information & technology XX% of fixed capital XXX XXX XX
Marketing & advertising XX% of operating cash cost at full capacity XXX XXX XX
Research & development XX% of operating cash cost at full capacity XXX XXX XX
Return on Capital Employed (ROCE)
ROCE assumptions can vary according to the industry sector and technology readiness. For this
specific process a ROCE percentage of XX% was assumed. This results in an increment of XXX
USD/metric ton in the product value.

Rev.0 E.1 Premium Edition | USA
Further Details
For more information about ROCE calculation, the reader is referred to
https://intrat.ec/m?f=/icc-methodology

Rev.0 E.2 Premium Edition | USA
Appendix F
Plant Cost Breakdowns
This appendix describes details of the plant cost which comprises the costs, directly or indirectly,
associated with the construction of the plant itself. Therefore, different breakdowns are presented
for a better understanding of the total cost associated with the construction of the plant under
analysis, as follows:
* ISBL cost by functional unit. This section provides the contribution of each functional unit
portrayed in the process block flow diagram in the cost of the inside battery limits (ISBL).
* OSBL cost by piece of equipment. This section provides a distribution of the investment
required for the construction of the areas that comprise the site surrounding infrastructure, as
well as it details the share of the costs of each component included in these areas.
* Plant cost breakdown per discipline. In this breakdown, the plant construction costs are
rearranged into an alternative perspective: direct process costs, indirect process costs and
project contingency.
ISBL Construction Cost Breakdown
In accordance with all the assumptions presented in this report, a cost estimate was developed for
each functional unit inside battery limits (ISBL). Table F.1 shows the share of each functional unit.

Rev.0 F.1 Premium Edition | USA
Table F.1 Process Unit (ISBL) Construction Cost by Functional Unit
Description %
XXXXXXXXX XX
XXXXXXXXX XX
XXXXXXXXX XX
XXXXXXXXX XX
XXXXXXXXX XX
XXXXXXXXX XX
XXXXXXXXX XX
XXXXXXXXX XX
Process Unit (ISBL) Construction Cost
Figure F.1 presents an illustration of the construction cost breakdown.
Figure F.1 Process Unit (ISBL) Construction Cost by Functional Unit

OSBL Construction Cost Breakdown
This analysis provides a more detailed explanation of the fixed capital associated with the process
described in the report. More specifically, it is focused on the investment required for the
construction of the site surrounding infrastructure, also referred to as Outside Battery Limits
(OSBL), comprising support buildings, auxiliary units used for providing and distributing utilities and
storage facilities. In accordance with the configuration previously presented, a cost estimate was
developed for each facility outside battery limits.
Figure F.2 presents OSBL investment broken down into each area. The investment estimated for
each area will be further detailed in the next topics.
Figure F.2 Site Infrastructure (OSBL) Construction Cost by Area

Construction Cost: Area 90 - Storage Installations
This section details the cost estimate associated with Area 90 - Storage Installations. The
components included in the estimate are detailed in the table below.
Table F.2 Area 90 - Storage Installations: Scope Description
Component Description
XXXXXXXXX XXXXXXXXX
XXXXXXXXX XXXXXXXXX
XXXXXXXXX XXXXXXXXX
The following chart illustrates how each component impacts the construction cost estimate for
this area.

Figure F.3 Storage Installations Construction Cost per Piece of Equipment

The cost of each component was based on the following assumptions:






Construction Cost: Area 91 - Utilities Facilities
This section details the cost estimate associated with Area 91 - Utilities Facilities. The
Table F.3 Area 91 - Utilities Facilities: Scope Description
XXXXXXXXX XXXXXXXXX
XXXXXXXXX XXXXXXXXX
XXXXXXXXX XXXXXXXXX
XXXXXXXXX XXXXXXXXX
XXXXXXXXX XXXXXXXXX
XXXXXXXXX XXXXXXXXX
XXXXXXXXX XXXXXXXXX
this area.

Figure F.4 Utilities Facilities Construction Cost per Piece of Equipment

The percentage associated with the remaining facilities is divided as follows:
* XXXXXXXXX - XX %
* XXXXXXXXX - XX %






Construction Cost: Area 92 - Support & Auxiliary Buildings
This section details the cost estimate associated with Area 92 - Support & Auxiliary Buildings. The
Table F.4 Area 92 - Support & Auxiliary Buildings: Scope Description
XXXXXXXXX XXXXXXXXX
XXXXXXXXX XXXXXXXXX
XXXXXXXXX XXXXXXXXX
XXXXXXXXX XXXXXXXXX
XXXXXXXXX XXXXXXXXX
XXXXXXXXX XXXXXXXXX
XXXXXXXXX XXXXXXXXX
XXXXXXXXX XXXXXXXXX
XXXXXXXXX XXXXXXXXX
this area.

Figure F.5 Support & Auxiliary Buildings Construction Cost per Piece of Equipment

The percentage associated with the remaining facilities is divided as follows:
* XXXXXXXXX - XX%
* XXXXXXXXX - XX%






Site Infrastructure Cost Summary
Table F.5 Site Infrastructure (OSBL) Construction Cost by Piece of Equipment
Component % of Total
XXXXXXXXX XX
XXXXXXXXX XX
XXXXXXXXX XX
Area 90 - Storage Installations XX
XXXXXXXXX XX
XXXXXXXXX XX
XXXXXXXXX XX
XXXXXXXXX XX
XXXXXXXXX XX
XXXXXXXXX XX
XXXXXXXXX XX
Area 91 - Utilities Facilities XX
XXXXXXXXX XX
XXXXXXXXX XX
XXXXXXXXX XX
XXXXXXXXX XX
XXXXXXXXX XX
XXXXXXXXX XX
XXXXXXXXX XX
XXXXXXXXX XX
XXXXXXXXX XX
Area 92 - Support & Auxiliary Buildings XX
Site Infrastructure (OSBL) Construction Cost 100.0

Plant Cost Breakdown per Discipline
Introduction
The primary objective of this analysis is to provide an alternative perspective on the plant capital
cost. This analysis presents the plant capital cost divided in three categories: (1) direct costs (all
material and labor costs associated with the process equipment); (2) indirect costs (defined by the
Association for the Advancement of Cost Engineering (AACE) Standard Terminology as those
“costs which do not become a final part of the installation, but which are required for the orderly
completion of the installation”); and (3) contingency.
It is important to highlight that the breakdown presented within this analysis refers exclusively to
the Plant Cost figure included in the report.
The composition of direct field costs and indirect costs are further detailed in the next topics.
Other fixed capital components, such as Owner's Cost, are not included in this breakdown.
The following chart presents the plant cost divided in each category described above.
Figure F.6 Plant Construction Cost Summary

Direct Costs Breakdown
Fundamentally, the direct process costs are the total installed equipment cost (from purchase to
installation, including the required installation bulks). They include the following disciplines: bare
equipment, equipment setting, piping, civil, steel, instrumentation & control, electrical, insulation,
and painting.
Accordingly, the chart below presents the direct costs broken down by aforementioned discipline.
Figure F.7 Direct Construction Costs by Discipline

Indirect Costs Breakdown
The indirect costs account for field indirects, engineering costs, overhead, and contract fees.
Accordingly, the chart below presents the indirect costs broken down by aforementioned items.
Figure F.8 Indirect Costs Summary

Plant Cost Breakdown Summary
The next table presents the detailed plant cost breakdown, based on the direct and indirect costs
approach. Two alternative views are presented in the table:
(1) % of BEQ. Each component is presented as a percentage of the bare equipment (BEQ) cost;
(2) % of Total. Each component is presented as a percentage of total plant cost.
Table F.6 Plant Construction Cost by Discipline
Component % of BEQ % of Total

Bare equipment (BEQ) XX XX
Equipment setting XX XX
Piping XX XX
Civil XX XX
Steel XX XX
Instrumentation & control XX XX
Electrical XX XX
Insulation XX XX
Painting XX XX
Direct costs XX XX
Engineering & procurement XX XX
Construction material & indirects XX XX
General & administrative overheads XX XX
Contract fee XX XX
Indirect costs XX XX
Total Process Capital (TPC) XX XX
Project Contingency (of TPC) XX XX
Total Plant Cost XX XX
The absolute cost of the plant is presented in the table “Plant Cost Summary” in “Chapter 8. Capital
Costs Summary.” It is worth noting that the process contingency presented in the aforementioned
table is included within each component listed in the table above.

Further Details
For further information about the components included in the plant cost breakdown, the
reader is referred to https://intrat.ec/m?f=/icc-methodology.

Appendix G
Plant Capacity Assessment - United States
This assessment presents the impact of a plant capacity change on the economic analysis
presented in this report. Additional capacity scenarios were analyzed using the same methodology
and compared to the base case presented in the report.
The assessment is divided into two parts: (1) a capital investment comparison, examining fixed
investment, working capital and additional capital requirements; and (2) an operating costs &
product value comparison.
Capital Cost for Different Capacities
The economic analysis presented was reproduced for a range of plant capacities in order to
estimate a curve that illustrates how capital investment varies with nominal plant output. This
curve is presented in Figure G.1.
The minimum, mid-range and maximum capacities from Figure G.1 are compared in detail in Table
G.1, which presents detailed capital cost figures to better portray how economy of scale impacts
the process under analysis.

Rev.0 G.1 Premium Edition | USA
Table G.1 Capital Investment Analysis for Different Capacities (MM USD)
Smaller Plant Base Larger Plant
Capacity (mt/yr) XXX 100.00 XXX
Inside battery limits (ISBL) XXX XXX XXX

Process contingency (XX% of ISBL) XXX XXX XXX
Outside battery limits (OSBL) XXX XXX XXX
Total process capital (TPC) XXX XXX XXX
Project contingency (XX% of TPC) XXX XXX XXX
Plant cost XXX XXX XXX
Owner’s cost XXX XXX XXX
Fixed capital XXX XXX XXX
Working capital XXX XXX XXX
Additional capital XXX XXX XXX
Total capital investment XXX XXX XXX
Figure G.1 Capital Investment Versus Plant Capacity

Operating Cost for Different Capacities
The operating costs and the product value were also estimated for a range of plant capacities,
resulting in Figure G.2.
A datasheet summarizing the process economics is reproduced in Table G.2, and it includes two
additional scenarios evaluated in this assessment.
Figure G.2 Operating Cost Versus Plant Capacity

Table G.2 Operating Cost & Product Value Analysis for Different Capacities (USD/mt)
Smaller Plant Base Larger Plant

Capacity (mt/yr) XXX 100.00 XXX
Operating rate (h/yr) XXX XXX XXX XXX
Annual production (mt/yr) XXX XXX XXX XXX
Operating costs
XXXXXXXXX XXX XXX XXX
XXXXXXXXX XXX XXX XXX
Gross raw materials cost XXX XXX XXX
Net raw materials cost XXX XXX XXX
Net utilities cost XXX XXX XXX
Operating variable costs XXX XXX XXX
Operating fixed costs XXX XXX XXX
Operating cash cost XXX XXX XXX
Depreciation XXX XXX XXX
Total operating cost XXX XXX XXX
Corporate overhead XXX XXX XXX
ROCE XXX XXX XXX
Product value XXX XXX XXX

Appendix H
Project Implementation & Construction Schedule
This appendix aims to present a preliminary project implementation schedule, encompassing the
period from the decision to invest to the start of commercial production.
This is divided into five major steps:
(1) Basic engineering;

(2) Detailed engineering;
(3) Procurement;
(4) Construction; and
(5) Start-up.
The duration of each project phase is detailed in Table H.1.
Table H.1 Project Phases Schedule
Phase Start Duration

Months after project started Months
Basic engineering XX XX
Detailed engineering XX XX
Procurement XX XX
Construction XX XX
Commissioning & start-up XX XX
Since the project phases overlap, the total project duration is not equal to the sum of each phase
duration. The Engineering, Procurement & Construction (EPC) period - from the basic engineering
start until the end of construction - is about XX months. The total project duration, also including
commissioning and start-up, is approximately XX months.

Rev.0 H.1 Premium Edition | USA
Figure H.1 illustrates the project implementation and construction schedule and clarifies the
overlaps among the distinct project phases.
Figure H.1 Implementation & Construction Schedule

Rev.0 H.2 Premium Edition | USA
Appendix I
Process Flow Diagrams & Equipment List
This chapter comprises a schematic representation of relevant operations of the process

examined in this report. It indicates process operations, main process streams, main pieces of
equipment and utilities consumed.
For better comprehension, the main conventions for equipment tags and symbols for lines used in
the process flow diagram are listed in Figure I.1 and Figure I.2.
X-1001
Equipment Number Inside Area
Area Number
Equipment Type
C – Column | E – Heat Exchanger | F – Furnace | K – Compressor | P – Pump | R – Reactor |
S – Special | T – Tank | V – Vessel
Figure I.1 Convention for Process Equipment Tags
Main process stream Secondary process stream or Energy stream or

Utility stream Computer signal
Figure I.2 Symbols for Lines
Table I.1 and Table I.2 present the different codes used along with their definitions.

Rev.0 I.1 Premium Edition | USA
Table I.1 Diagram Legend - Utilities
Code Definition
BFW Boiler feed water
CW Cooling water
DW Demineralized water
FU Fuel
HTF Heat transfer fluid
N2 Nitrogen
O2 Oxygen
PC Process condensate
PW Process water
RF Refrigerant
RW Refrigerated water
ST Steam
Table I.2 Diagram Legend - Equipment Type
Code Definition
C Column
E Heat exchanger
F Furnace
K Compressor
P Pump
R Reactor
S Special
T Tank
V Vessel
Furthermore, most of the symbol standards adopted in the development of the diagram are
presented in the next figures.

Fluidized Reactor Tubular Reactor Multi-Tubular Fixed-Bed
Reactor Reactor
Horizontal Agitated-Jacketed
Vertical Vessel Agitated Vessel Carrying Vessel Settler Clarifier
Vessel Vessel
Flat Roof Tank Conical Roof Tank Open Tank Floating Roof Tank Sphere Tank Gas Holder Bin
Figure I.3 Equipment Symbols - Reactors & Vessels
Heat Heat U-Tube Heat Plate-Type Finned Tubes

Exchanger Exchanger 2 Kettle Reboiler Air-Cooler
Exchanger Exchanger Exchanger
Double Pipe Furnace Evaporator

Cooler Heater Coil Fired Heater
Heat Exchanger
Plate-Fin Cooling Air Cooling Barometric Chilling

Evaporator Refrigerators Boiler
Exchanger Tower Evaporator Condenser
Figure I.4 Equipment Symbols - Heat Exchangers

General Reciprocating Diaphragm Rotary Turbo Roller Vane
Screw Compressor
Compressor Compressor Compressor Compressor Compressor Compressor
Centrifugal Pos. Displacement Liquid Ring

Electric Motor General Fan Radial Fan Axial Fan
Compressor Compressor Compressor
Centrifugal Pos. Displacement Reciprocating

General Pump Gear Pump Screw Pump Diaphragm Pump
Pump Pump Pump
Vacuum
Pump Compressor Turbine Helical Rotor Liquid Jet Pump Ejector
Figure I.5 Equipment Symbols - Compressors & Pumps
Extraction Fluidized Bed

Column Packed Column 1 Tray Column
Column Column
Figure I.6 Equipment Symbols - Columns

Solid Bowl Rotatory
Filter Cyclone Prilling Tower Centrifuge Screen
Centrifuge Feeder
ION
Filter Rotary Vacuum Briquetting Fixed-Bed Ion-Exchange

Sieve Filter Belt-Filter
Press Machine Filter Filter
BIO
Spray
Biological Elevator 1 Conveyor Screw Conveyor
Dryer
Filter
Drying Fluid-Bed
Extruder
Oven Dryer
Figure I.7 Equipment Symbols - Solids Processing

IMPORTANT NOTICE PROVIDER
THIS PFD IS BASED ON NON-CONFIDENTIAL
INFORMATION. DETAILS (INDUSTRIAL SECRETS AND/OR
CHANGES NOT REPORTED IN THE LITERATURE) ARE PROCESS FLOW DIAGRAM
BASED ON INTRATEC PROCESS SYNTHESIS KNOWLEDGE,
IN SUCH A WAY THAT DIFFERENCES MAY EXIST, PHTHALIC ANHYDRIDE PRODUCTION FROM
NEVERTHELESS, THIS PFD RELIABLY PORTRAYS THE NAPHTHALENE
PROCESS, CONCEPTUALLY. FOR A BETTER
UNDERSTANDING, SEE THE RELATED REPORT. PAGE
1/2 www.intratec.us
IMPORTANT NOTICE PROVIDER
THIS PFD IS BASED ON NON-CONFIDENTIAL
INFORMATION. DETAILS (INDUSTRIAL SECRETS AND/OR
CHANGES NOT REPORTED IN THE LITERATURE) ARE PROCESS FLOW DIAGRAM
BASED ON INTRATEC PROCESS SYNTHESIS KNOWLEDGE,
IN SUCH A WAY THAT DIFFERENCES MAY EXIST, PHTHALIC ANHYDRIDE PRODUCTION FROM
NEVERTHELESS, THIS PFD RELIABLY PORTRAYS THE NAPHTHALENE
PROCESS, CONCEPTUALLY. FOR A BETTER
UNDERSTANDING, SEE THE RELATED REPORT. PAGE
2/2 www.intratec.us
Appendix J
About Intratec
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COMMODITY PRODUCTION COSTS

PREMIUM EDITION | USA

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Copyright 2024 by Intratec Solutions LLC

* Raw materials consumption, products generation, and labor requirements.

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* Improvement: structural changes common to all Intratec Commodity Costs of Production

Report Revision History – Series XXXX

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XX XXXXXX XXXXXXXXXXX XXXXXXXXX XXXXXXXXXX XXXXXXX XXXXXXXX XX

XX XXXXXX XXXXXXXXXXX XXXXXXXXX XXXXXXXXXX XXXXXXX XXXXXXXX XX

XX XXXXXX XXXXXXXXXXX XXXXXXXXX XXXXXXXXXX XXXXXXX XXXXXXXX XX

XX XXXXXX XXXXXXXXXXX XXXXXXXXX XXXXXXXXXX XXXXXXX XXXXXXXX XX

XX XXXXXX XXXXXXXXXXX XXXXXXXXX XXXXXXXXXX XXXXXXX XXXXXXXX XX

XX XXXXXX XXXXXXXXXXX XXXXXXXXX XXXXXXXXXX XXXXXXX XXXXXXXX XX

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Understanding Intratec Commodity Production Costs

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Intratec Commodity Production Costs Support

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About This Report

Item Code Description

Product ICC Intratec Commodity Production Costs

Volume 37 Phthalic Anhydride

Issue B Phthalic Anhydride Production from Naphthalene

Edition PREM Corresponds to the Premium Edition of the report

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* The reports are not based on any kind of confidential information.

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List of Figures xiii

Acronyms & Abbreviations xvii

Executive Summary 1.1

About Phthalic Anhydride 1.1

Phthalic Anhydride Production Process 1.2

Economic Analysis 1.3

About Phthalic Anhydride 2.1

Commercial Forms & Applications 2.2

Phthalic Anhydride Production Routes 2.3

Process Overview 3.1

Technology Maturity Assessment 3.1

Product(s) Description 3.3

Inputs Description 3.3

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Process Unit 5.1

Block Flow Diagram 5.2

Site Infrastructure 6.1

Process Consumptions & Labor Requirements 7.1

Key Input & Output Figures 7.1

Labor Requirements 7.2

Capital Costs Summary - United States 8.1

Total Capital Investment 8.3

Operating Costs Summary - United States 9.1

Operating Variable Costs 9.3

Total Operating Cost 9.3