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PROCESS
SELECTION
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PRODUCTION OF 2-ETHYLHEXYL ACRYLATE (2-EHA) VIA

DIRECT ESTERIFICATION PROCESS

I. INTRODUCTION

2-Ethylhexyl Acrylate (2EHA), also known as 2-ethylhexyl propenoate,

is an acrylic ester with a molecular weight of 184.28 g/mol. is a colorless,

volatile liquid that is mildly soluble in water but completely soluble in alcohol,

ethers, and the majority of organic solvents (Komo et al., 2013). It has very

good film formation property for which it is used in paints, adhesives, and

coating applications (Haloi & Singha, 2011).

Most frequently, esters are produced by reacting a carboxylic acid with

an alcohol in the absence of water. In general, the reaction is characterized by a

high yield and minimal side reactions. Other techniques for ester production use

carboxylic acid derivatives including acid anhydride, acid chlorides, nitrile, and

amide. Additionally, ester may be derived from unsaturated hydrocarbons and

aldehydes.

2EHA is usually produced by esterifying acrylic acid (AA) with 2EH in

the presence of a catalyst. In the esterification process, the role of the catalyst is

to speed the chemical reaction by decreasing the activation energy needed for

the reaction. Esterification is one of the most significant reactions in the

chemical industry in terms of volume. Probably in excess of 500 distinct ester

products are offered for sale by over 100 manufacturers. Plasticizers, tastes and
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scents, insecticides, solvents, monomer for resins, and high molecular weight

polymer are examples of these materials.

Table 2: Properties of 2-Ethylhexyl Acrylate (2EHA)

Molecular Formula C11H20O2 or CH2=CHCOOC8H17

Molecular Weight 184.3 g/mol

Density 0.885 g/cm3 at 20 °C

Boiling Point 229 °C (1013 kPa)

Melting Point approx. – 90 °C

Viscosity 1.7 mPa ∙ s at 20 °C

Solubility 0.1 g/L

II. Reaction Mechanism

       Glycerol is converted to acrolein by a dehydration process, which takes

place in the gas phase in the presence of a catalyst:

C3H8O3 → C3H4O + 2H20

       The conversion of acrolein into acrylic acid by the use of oxygen in the

oxidation process. An oxidation process may be carried out because oxygen is

present in the environment:

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C3H4O + 12O2 C3H4O2

       Acrylic Acid along with 2-ethylhexanol and catalyzed by sulfuric acid will

undergo the process of direct esterification. 

C3H4O2 +C8H18O +H2SO4 →  C11H20O2 + C8H18O4S

       The hydrolyzer reactor is added to decompose the 2-ethylhexyl hydrogen

sulphate to sulfuric acid and 2-ethylhexanol. The reaction mechanism of

hydrolysis is shown below:

C8H18O4S C8H18O +H2SO4

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III. Process Flow Diagram

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Fi

gure 1: Section 100 Production Acrylic Acid

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Figure 1: Section 200 Production of 2-Ethylhexyl Acrylate

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IV. Process Description

Section 100: Production of Acrylic Acid

       Two streams of water and glycerol are fed into a Mixing Tank to form a

glycerol solution and it will be heated by a Heat Exchanger before entering the

Dehydration Reactor along with another stream of air. The reactor has a

temperature and pressure of 331℃ and 2 bars respectively to convert glycerol

to acrolein. The product stream of the reactor consists of a mixture comprising

acrolein, water, nitrogen, oxygen, acetaldehyde, Co, and CO2 at 320 °C.

     The latter stream is cooled to 151°C using a heat exchanger and it will be

fed to the absorption column to separate heavy by-products into non-

condensable light compounds. The heavy by-products exiting at the upstream of

the absorption column at 102°C is sent to a condenser which cools it to 79°C

then to a flash pot to separate the gas phase from the liquid phase wherein this

liquid phase is sent back to the absorption column.

       The light compounds exiting at the downstream of the Absorption tower

will be injected to a stripping column at 103℃ along with a stream of Air at

90℃ and 1.7 bar. The bottom outlet of the stripping column recovered water,

acetic acid, and formic acid at 55℃. The recovered compounds on the upper

part of the stripping column will be mixed to the gas product of the flash pot

and sent to a heat exchanger to increase the temperature to 160℃ and injected

to the oxidation reactor for the conversion of acrolein to acrylic acid. The outlet
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of the reactor is directed to a heat exchanger to decrease the temperature from

245 ̊C to 157 ̊C.

     The acrylic acid, water, nitrogen, oxygen, CO, CO2 and acetic acid are the

product of oxidation and will be sent to an absorption column, wherein the top

stream will be cooled from 102 ̊C to 53 ̊C. After condensing, the phases will be

separated by a separator pot, wherein liquid phase will be recycled back to the

absorption column while the gas phase will undergo exhaust gas scrubber to

further separate CO and CO2 from other by-products before the latter are

released to the atmosphere while CO and CO2 will go directly to wastewater.

       The outlet at the bottom of the absorption column recovered acrylic acid

and water. The acrylic acid will be further purified. In the first purification,

acrylic acid will enter the first distillation column that operates at an absolute

pressure of 1.13 bars. The temperature at the liquid stream should not exceed

95°C to limit the formation of acryloxy propionic acid and acrylic acid

polymers. This stream will go directly to wastewater. On the other hand, the gas

stream is condensed at a condenser at the minimum temperature to obtain

higher purity of acrylic acid and will be subjected to second purification. The

gas stream from the first distillation will enter the second distillation, the gas

phase will be condensed and recycled back to the column while the liquid

stream will pass through a reboiler to obtain a more concentrated Acrylic Acid.

Section 200: Production of 2-ethylhexyl Acrylate

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        Acrylic acid and 2-ethylhexanol are fed into the mixer and the mixture is

heated using a heat exchanger before it enters the esterification reactor. The

product will be separated using a settling, the 2-ethylhexanol will be recovered

using a hydrolysis reactor, neutralizer and a distillation column.

        The other stream of the settling process will undergo three (3) stage

purification to obtain high purity of the product. The bottom outlet of the

distillation column will go directly to the aerator to break down the nutrients

and other organic compounds that can result in the growth of any harmful

organisms. After the aeration process, it will undergo clarifying. 

       The top stream of the distillation column will be condensed and mixed

before it will be filtered the 2-ethylhexyl acrylate from other compounds.

V. Equipment Utilized

Name of Equipment Code Quantity

Mixer M 3

Heat Exchanger HX 5

Dehydration Reactor DHR 1

Absorption AC 2

Scrubber SB 1

Oxidation Reactor OR 1

Flash Drum FD 1
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Separator SC 1

Extraction Column EC 1

Storage Tank ST 4

Distillation Column DC 5

Continuous Stirred-Tank Reactor CSTR 1

Hydrolysis HTR 1

Neutralizer NTR 1

Dryer DR 1

Filter F 1

Clarifier CL 1

Aerator A 1

Centrifugal Separator CS 1

Separator S 1

Condenser C 5

Table 3: Equipment used in Production of 2-Ethylhexyl Acrylate from Acrylic

Acid and 2-Ethylhexanol via Esterification Process
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VI. Raw Materials 

Figure.     Zinc Oxide

(Source: Wikipedia.com)

Zinc oxide is an inorganic compound with the formula ZnO. It is a white

powder that is insoluble in water. ZnO is used as an additive in numerous

materials and products including cosmetics, food supplements, rubbers,

plastics, ceramics, glass, cement, lubricants, paints, ointments, adhesives,

sealants, pigments, foods, batteries, ferrites, fire retardants, and first-aid tapes.

Although it occurs naturally as the mineral zincite, most zinc oxide is produced

synthetically, zinc oxide is a largely inert, white compound which is used very

widely as a bulking agent or filler, and as a white pigment. It is found in some

rubber, glass and ceramic products, and finds use in the chemical industry as a

catalyst. It is also used in paints as a corrosion inhibitor and for mildew control.
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Figure. Di isopropyl Ether

(Source pubchem.ncbi.gov)

Di isopropyl ether is a secondary ether that is used as a solvent. It is a colorless

liquid that is slightly soluble in water, but miscible with organic solvents. It is

used as an extractant and an oxygenate gasoline additive. It is obtained

industrially as a byproduct in the production of isopropanol by hydration of

propylene. Di isopropyl ether is sometimes represented by the abbreviation

DIPE.
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Figure. Sulfuric Acid

(Source study.com))

Sulfuric acid, sulfuric also spelled sulphuric (H2SO4), also called oil of vitriol,

or hydrogen sulfate, dense, colorless, oily, corrosive liquid; one of the most

commercially important of all chemicals. Sulfuric acid is prepared industrially

by the reaction of water with sulfur trioxide (see sulfur oxide), which in turn is

made by chemical combination of sulfur dioxide and oxygen either by the

contact process or the chamber process. In various concentrations the acid is

used in the manufacture of fertilizers, pigments, dyes, drugs, explosives,

detergents, and inorganic salts and acids, as well as in petroleum refining and

metallurgical processes. In one of its most familiar applications, sulfuric acid

serves as the electrolyte in lead–acid storage batteries.

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Figure. Glycerol
(Source: study.com)

Glycerol is a colorless, odorless liquid with a sweet taste. It is viscous at room

temperature and non-toxic in low concentrations. Glycerol is used in a number

of industrial applications, in the pharmaceutical industry, in cosmetics and

personal care products, in the production of resins, detergents, plastics and

tobacco and as a humectant in food. Its use as a commercially important

chemical began with its application in the production of dynamite. Dynamite

was necessary in the discovery and extraction of underground minerals, and in

the construction of infrastructure. Therefore, it propelled industrial

development.
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Figure. Natural Zeolite

(Source: earthmagzine.org)

Are hydrated aluminum silicate frameworks with pores occupied by water,

alkali, and alkaline earth-metal cations Zeolites are among the most important

inorganic cation exchangers and are used in industrial applications for water

and wastewater treatment, catalysis, nuclear waste, agriculture, animal feed

additives, and in biochemical applications. 

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VII. Plant Economy

This section shows the estimated total capital investment and annual

production for manufacturing of 2-Ethylhexyl Acrylate from Acrylic Acid and

2-Ethylhexanol via the Esterification Process.

TOTAL CAPITAL INVESTMENT

The estimated fixed cost for the production of 2-Ethylhexyl Acrylate

from Esterification Process is calculated using Lang Method, factor from

Perry’s Chemical Engineer’s Handbook 8th Edition.

Table 4: Lang Factors (Green and Perry, 2008)

TYPE OF PLANT FIXED CAPITAL TOTAL CAPITAL

INVESTMENT INVESTMENT

Solid Processing 4.0 4.7

Solid - Fluid 4.3 5.0

Processing

Fluid Processing 5.0 6.0

The formula for the computation of the Fixed Capital Cost below was

retrieved from Chemical Engineering Design Volume 6 authored by Coulson

and Richardson.

C f =f L C e
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Where:

C f = fixed capital cost

f L= Lang factor

C e= total delivered cost of all major equipment items 

The estimated prices of the minor and major equipment are based on the

prices available from various online sources. 

Exchange Rate: 1 USD = PHP 57.58 (September 2022)

Table 5. Equipment Cost for the Production of 2-Ethylhexyl Acrylate from

Acrylic Acid and 2-Ethylhexanol via Esterification Process

NAME OF QUANTITY EQUIPMENT TOTAL

EQUIPMENT COST (PHP) EQUIPMENT
COST (PHP)

Mixer 3 255,690 1,278,450.00

Heat Exchanger 5 120,630.1 603,150.5

Dehydration 1 34,432.84 172,164.2

Reactor

Absorption 2 500,000 2,500,000.00

Column

Scrubber 1 113,640 568,200.00

Oxidation Reactor 1 227,320  1,136,600.00

Separator 2 1,136,600 2,841,500.00

Extraction Column 1 142,000  710,000.00

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Storage Tank 4 660,000 3,300,000.00

Distillation 5 1,420,000 7,100,000.00

Column

Continuous 1 373,307.4 1,866,537.00

Stirred-Tank
Reactor

Hydrolysis 1 284,150.00  1,420,750

Neutralizer 1 61,373.00 306,865.00

Dryer 1 852,450.00 4,262,250.00

Filter 1 284,100.00 1,420,500.00

Clarifier 1 222,243.00 1,111,215.00

Aerator 1 34,200 171,000.00

Centrifugal 1 1,073,000 5,365,000.00

Separator

Condenser 5 99,455.00 497,275.00

Total Purchased Cost of 7,241,121 36,631,456.70

Equipment (PCE) 

(Source: alibaba.com, eastpower.com, dir.indiamart.com, connect2india.com,

made-in-china.com)

Table 6: Factors for the estimation of fixed capital cost (Source: Chemical
Engineering Design Vol 6 by Coulson and Richardson)

Item Process Type

Fluid Solid- Solids

fluids

1. Major Equipment PCE PCE PCE

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f1 Equipment Erection 0.4 0.45 0.50

f2 Piping 0.7 0.45 0.20

f3 Instrumentation 0.2 0.15 0.10

f4 Electrical 0.1 0.10 0.10

f5 Buildings, Process 0.15 0.10 0.05

f6 Utilities 0.5 0.45 0.25

f7 Storages 0.15 0.20 0.25

f8 Site development 0.05 0.05 0.05

f9 Ancillary buildings 0.05 0.20 0.35

2. Total Physical Plant Cost (PPC) PPC=PCE 3.30 3.15 2.8

(1+f1+…+f9) =PCEx

f10 Design and Engineering 0.30 0.25 0.20

f11 Contractor’s fee 0.05 0.05 0.05

f12 Contingency 0.10 0.10 0.10

Fixed capital= PPC (1+f10+f11+f12) 

== 𝑃𝐶𝐸 x 1.45 1.40 1.35

A. TOTAL PHYSICAL PLANT COST (PPC)

𝑃𝑃𝐶 = 𝑃𝐶𝐸 (1 + 𝑓 1 + 𝑓 2 + 𝑓 3 + 𝑓 4 + 𝑓 5+ 𝑓 6 + 𝑓 7 + 𝑓 8 + 𝑓 9 )

𝑃𝑃𝐶 = ₱ 36,631,456.70 (3.3)  

𝑃𝑃𝐶 =₱ 120,883,807.1

B. FIXED CAPITAL COST (FCC)

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𝐹𝐶𝐶 = 𝑃𝑃𝐶 ( 1 + ƒ 10 + ƒ 11 + ƒ 12 )

FCC= ₱120,883,807.1 (1.45) 

FCC= ₱ 175,281,520.3

C.  WORKING CAPITAL COST (WCC) 

𝑊𝐶𝐶 = 𝐹𝐶𝐶 (0.5)

𝑊𝐶𝐶 = ₱ 17,5281,520.3 (0.5)

𝑊𝐶𝐶 = ₱ 87,640,760.15

D.  TOTAL CAPITAL INVESTMENT (TCI)

TCI = FCC + WCC

TCI = ₱ 175,281,520.3 + ₱ 87,640,760.15

TCI = ₱ 262,922,280.45

E. FIXED COST

Maintenance Cost (MC) 

𝑀𝑎𝑖𝑛𝑡𝑒𝑛𝑎𝑛𝑐𝑒 𝐶𝑜𝑠𝑡 = (0. 10)(𝐹𝐶𝐶) 

𝑀𝑎𝑖𝑛𝑡𝑒𝑛𝑎𝑛𝑐𝑒 𝐶𝑜𝑠𝑡 = (0. 10) * ( ₱ 175,281,520.3) 

𝑀𝑎𝑖𝑛𝑡𝑒𝑛𝑎𝑛𝑐𝑒 𝐶𝑜𝑠𝑡 = ₱17,528,152.03

Operating Labor Cost (OLC)

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The estimated operating labor required for a plant with a capacity of

4.20 metric tons of product per day and have an average condition is 35

employee-hours/day/processing steps. Considering 300 working days of

annual operation and ten processing steps, the current daily minimum

wage rate per hour is PHP 435 per hour. 

Figure 1. Operating Labor Requirements for Chemical Process

Industries (Source: Peter & Timmerhaus, 1991)

Table 7. Latest Wage Orders and Implementing Rules Issued by the

Regional Boards as of June 21, 2022 (Wage Order No. IVA-19

Department of Labor and Employment, 2022)

INDICAT SECTOR
OR

RETAIL &
NON- AGRICULTURE SERVICE
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AGRICULT ESTABLISHME
URE NTS

PLANTATI NON-
ON PLANTATI
ON

REGION 435 401 401 350

IV-A

Calculating the operating labor costs using data for manpower: 

= (35 employee   hours day processing steps )x(300 working days year)x(PHP

435.00employee-8 hours)x(2 processing steps)(1 year operation)

Operating Labor Cost = ₱ 1,141,875.00

Laboratory Cost (LC)

Laboratory cost comprises laboratory analyses necessary for the

evaluation and quality management of processes. A rough estimate of the cost

is 20 to 30 percent of the operational labor cost, which is equivalent to 2 to 4

percent of the overall production cost. (R.K. Sinnott, Chemical Engineering

Design, Vol. 6, 2005) For the computation of the laboratory cost, the average

percentage will be used. Therefore: 

Laboratory Cost = (OLC)(0.23)

Laboratory Cost = (₱ 1,141,875.00) (0.23)

Laboratory cost = ₱ 262,631.25

Supervision Cost (SC)

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Supervision cost involves the entire management that is directly

involved in the plant's operation.. The size of the facility and the nature of the

operation dictate the number of people needed. Four to five shift forepersons, a

general foreman, an area supervisor, and an assistant are typical members of a

unit management team. The cost of supervision is around 20% of the cost of

operational labor (R.K. Sinnott, Chemical Engineering Design, Vol. 6, 2005).

Therefore:

Supervision Cost = OLC (0.20)

Supervision Cost = ₱ 1,141,875.00 (0.20)

Supervision Cost = ₱ 228,375.00

Plant Overheads (PO)

Plant overheads include all general operating costs not covered by

headings, such as general management, plant security, medical, canteen, general

electrical staff, and safety. The total labor cost: operating, maintenance, and

supervision is usually used to estimate the plant overhead cost. A typical range

would be 50–100% of operating labor costs. (R.K. Sinnott, Chemical

Engineering Design, Vol. 6, 2005). Therefore:

𝑃𝑙𝑎𝑛𝑡 𝑂𝑣𝑒𝑟ℎ𝑒𝑎𝑑𝑠 = (𝑂𝐿𝐶) (0. 50)

𝑃𝑙𝑎𝑛𝑡 𝑂𝑣𝑒𝑟ℎ𝑒𝑎𝑑𝑠 = (₱ 1,141,875.00) (0.50) 

𝑃𝑙𝑎𝑛𝑡 𝑂𝑣𝑒𝑟ℎ𝑒𝑎𝑑𝑠 = ₱ 570,937.50

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Capital Charges (CC)

A rough of the capital charge cost can be taken as ten percent of the

fixed capital cost. (R.K. Sinnott, Chemical Engineering Design, Vol. 6, 2005).

Therefore:

Capital Charges = FCC (0.10)

Capital Charges =  ₱175,281,520.3 (0.10)

Capital Charges = ₱17,528,152.03

Local Taxes (LT)

Local taxes are calculated on the value of the site. A typical figure

would be 1 to 2 percent of the fixed capital cost. (R.K. Sinnott, Chemical

Engineering Design, Vol. 6, 2005). For the computation of the local taxes, the

average will be used. Therefore:

Local Taxes = ₱175,281,520.3 (0.015)

LT = ₱175,281,520.3 (0.015)

LT = ₱ 2,629,222.80

Insurance(I)
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An estimate of the insurance cost can be taken as 1 to 2 percent of the fixed

capital cost. (R.K. Sinnott, Chemical Engineering Design, Vol. 6, 2005). The

average computation value will be used. Therefore:

 Insurance = FCC (0.015)

I =₱175,281,520.3 (0.015)

I = ₱ 10, 947,502.53

License Fee/ Royalty Fee (LF/RF)

A rough estimate of the license fee/royalty fees can be taken as one to

two percent of the fixed capital cost. License Fee/ Royalty Fee (LF/RF) (R.K.

Sinnott, Chemical Engineering Design, Vol. 6, 2005). For the computation

average value will be used. Therefore:

𝐿𝑖𝑐𝑒𝑛𝑠𝑒 𝐹𝑒𝑒/𝑅𝑜𝑦𝑎𝑙𝑡𝑦 𝐹𝑒𝑒𝑠 = FCC (0.015)

𝐿𝑖𝑐𝑒𝑛𝑠𝑒 𝐹𝑒𝑒/𝑅𝑜𝑦𝑎𝑙𝑡𝑦 𝐹𝑒𝑒𝑠 = ₱175,281,520.3 (0.015)

𝐿𝑖𝑐𝑒𝑛𝑠𝑒 𝐹𝑒𝑒/𝑅𝑜𝑦𝑎𝑙𝑡𝑦 𝐹𝑒𝑒𝑠 = ₱ 10, 947,502.53

Table 8. Summary of Fixed Cost for Process 1 

FIXED COST COST (PHP)

Maintenance Cost ₱17,528,152.03

Operating Labor Cost ₱ 1,141,875.00

Laboratory Cost ₱ 262,631.25

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Supervision Cost  ₱ 228,375.00

Plant Overheads ₱ 570,937.50

Capital Charges ₱17,528,152.03

Local Taxes ₱ 2,629,222.80

Insurance ₱ 10, 947,502.53

License Fee/ Royalty Fee  ₱ 10, 947,502.53

TOTAL FIXED COST ₱ 6,1784,350.67

F. VARIABLE COSTS 

Miscellaneous Operating Materials (MOM)

Miscellaneous Operating Materials = Maintenance Cost (0.10)

MOM =₱17,528,152.03 (0.10)

MOM = ₱ 1,752,815.203

Cost of Raw Materials (RMC) 

For a plant capacity of 4.20 MT of product per day, 

Exchange Rate: 1 USD = PHP 57.58 (September 2022)

Table 9. Prices of Raw Materials (Source: chemanalyst.com, rf .org,

alibaba.com, chemanalyst.com, basemetal.ee)

RAW MATERIALS PRICE PER TON (USD) PRICE PER TON (PHP)

Glycerol 800 USD 46,064 PHP

Zinc Oxide 750 USD 43,335 PHP

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Di-isopropyl ether 2130 USD 122,645.4 PHP

Zeolite 100.2 USD  5,769.516 PHP

Sulfuric Acid 89 USD 5,124.62 PHP

TOTAL 3,869.2 USD 222,938.536 PHP

Table 10. Summary of Variable Cost for Process 1 

VARIABLE COST COST (PHP)

Cost of Raw Materials  ₱ 222,938.536

Miscellaneous Operating Materials ₱ 1,752,815.203

TOTAL VARIABLE COST  ₱ 1,975,753.739

Direct Production Cost (DPC)

𝐷𝑃𝐶 = 𝑇𝑜𝑡𝑎𝑙 𝑉𝑎𝑟𝑖𝑎𝑏𝑙𝑒 𝐶𝑜𝑠𝑡 + 𝐹𝑖𝑥𝑒𝑑 𝐶𝑜𝑠𝑡 

𝐷𝑃𝐶 = ₱ 1,975,753.739 + ₱ 6,1784,350.67

𝐷𝑃𝐶 = ₱ 63,760,104.409

Sale Expense 

𝑆𝑎𝑙𝑒𝑠 𝐸𝑥𝑝𝑒𝑛𝑠𝑒 = (0. 20) (𝑇𝑜𝑡𝑎𝑙 𝑉𝑎𝑟𝑖𝑎𝑏𝑙𝑒 𝐶𝑜𝑠𝑡 + 𝐹𝑖𝑥𝑒𝑑 𝐶𝑜𝑠𝑡)

 𝑆𝑎𝑙𝑒𝑠 𝐸𝑥𝑝𝑒𝑛𝑠𝑒 = 0. 20 (₱ 1,975,753.739 + ₱ 6,1784,350.67)

 𝑆𝑎𝑙𝑒𝑠 𝐸𝑥𝑝𝑒𝑛𝑠𝑒 = ₱ 12,752,020.88

General Overheads 

𝐺𝑒𝑛𝑒𝑟𝑎𝑙 𝑂𝑣𝑒𝑟ℎ𝑒𝑎𝑑𝑠 = 0. 30(𝑇𝑜𝑡𝑎𝑙 𝑉𝑎𝑟𝑖𝑎𝑏𝑙𝑒 𝐶𝑜𝑠𝑡 + 𝐹𝑖𝑥𝑒𝑑 𝐶𝑜𝑠𝑡) 

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𝐺𝑒𝑛𝑒𝑟𝑎𝑙 𝑂𝑣𝑒𝑟ℎ𝑒𝑎𝑑𝑠 = 0. 30( ₱ 1,975,753.739 + ₱ 6,1784,350.67)

𝐺𝑒𝑛𝑒𝑟𝑎𝑙 𝑂𝑣𝑒𝑟ℎ𝑒𝑎𝑑𝑠 = ₱ 19,128,031.3227

Indirect Production Cost (IPC) 

𝐼𝑃𝐶 = 𝑆𝑎𝑙𝑒𝑠 𝐸𝑥𝑝𝑒𝑛𝑠𝑒 + 𝐺𝑒𝑛𝑒𝑟𝑎𝑙 𝑂𝑣𝑒𝑟ℎ𝑒𝑎𝑑𝑠

 𝐼𝑃𝐶 = ₱ 12,752,020.88 + ₱ 19,128,031.3227

 𝐼𝑃𝐶 = ₱ 31,880,052.20

Annual Production Cost (APC)

𝐴𝑃𝐶 = 𝐷𝑖𝑟𝑒𝑐𝑡 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝐶𝑜𝑠𝑡 + 𝐼𝑛𝑑𝑖𝑟𝑒𝑐𝑡 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝐶𝑜𝑠𝑡 

𝐴𝑃𝐶 = ₱ 63,760,104.409 + ₱ 31,880,052.20

𝐴𝑃𝐶 = ₱ 95,640,156.61

Production Cost

Production Cost = APC (Plant Capacity/Day)(300 working days/year)

Production Cost = ₱ 95,640,156.61(4.20 MT/Day)(300 working

days/year)/

Production Cost = ₱ 75,904.89

The annual production cost required for the plant to produce 4.20

MT/day of 2-Ethylhexyl Acrylate via Direct esterification process is estimated

to be ₱ 95,640,156.61and a production cost of ₱75,904.89 per metric ton.  Most

of the amounts were allotted for direct production cost.

 Technological Institute of the Philippines

G. MANUFACTURABILITY 

The table presented below shows the summary for the manufacturability

of Process 1: Production of 2-Ethylhexyl Acrylate via Direct Esterification

Process.

Table 11. Summary of Manufacturability of Process 1 

CRITERIA DISCUSSION 

Number of The following are the 18 intensive equipment included

Intensive in the production of 2-ethylhexyl Acrylate via Direct
Equipment Esterification:
 Dehydration Reactor (1)
 Heat exchangers (5)
 Absorption Column (1)
 Scrubber (1)
 Distillation Column (5)
 Oxidation Reactor (1)
 Esterification Reactor (1)
 Centrifuge (1)
 Hydrolysis Reactor (1)
 Neutralizer (1)

Purity The purity of 2-ethylhexyl acrylate produced from

direct esterification process is 99.7%.

Yield The 2-ethylhexyl acrylate obtained from direct

esterification process has a product yield of 90%

By-products Formic acid and Acetic acid are the by-products in

Section 100 of this process.

H. SUSTAINABILITY 

Availability of Raw Material 

The availability of these raw materials is the most important factor in

the process selection. Throughout the production, the supply of the raw material
 Technological Institute of the Philippines

in the Philippines is considered. The raw materials are readily available in the

Philippines because of the existence of many manufacturing plants producing it

as well as various suppliers. Listed below are the possible companies where the

raw materials can be purchased locally. 

Table 12. Suppliers of Raw Material for the production of 2-ethylhexyl acrylate

(2-EHA) via Esterification process

RAW SUPPLIER
MATERIALS 

Zinc Oxide  SBS Philippines Corporation

Location No. 10 Resthaven Street, San Francisco Del
Monte, Quezon City
 Republic Chemical Industries, Inc. 
731 Aurora Blvd, New Manila, Quezon City,
1112 Metro Manila

Diisopropyl Ether  SBS Philippines Corporation

Location No. 10 Resthaven Street, San Francisco Del
Monte, Quezon City

Sulfuric Acid  Rene’s Radiator and Chemical Supply

Location  Bulua,Misamis Oriental,Philippines
 Obetech Pacific
PH8 VGP Center 6772 Ayala Avenue,
Makati,Metro Manila

Glycerol Location   Wills International Sales Corporation 

 P2, 11th Corporate Center 11th Avenue Cor
Triangle Drive, Triangle Dr, Taguig, 1635 Metro
Manila
 Brenntag Ingredients Inc. 
16th Floor Asian Star Bldg. 2402-2404, Asean
Drive, Filinvest City,1781, Alabang, Muntinlupa
City, Philippines 
 Technological Institute of the Philippines

4-methoxyphenol  RedaChem Ingredients Philippines, Inc. 

Location 634 26th Street corner 9th Avenue 21st Floor,
Tower 1, High Street South Corporate Plaza,
Taguig, 1634 Metro Manila

Phenothiazine  CCT Chemicals Inc.

Unit 302 Alabang Business Tower, Madrigal
Business Park, 1216 Acacia Avenue, Alabang,
Muntinlupa City

Natural Zeolite  Lithos Manufacturing, OPC

Sta. Maria, Bulacan

Figure 1. Global Market Size of Zinc Oxide

(Source: Grand View Research) 

The global zinc oxide market size was valued at USD 4.43 billion in 2021 and

is projected to grow at a compound annual growth rate (CAGR) of 6.9% from

2022 to 2030. This growth can be attributed to the properties of zinc oxide

(ZnO), such as high thermal conductivity, high refractive index, UV protection,

antibacterial, and binding properties. The product is used in a wide range of

industries. Some of these include rubber, ceramics, pharmaceuticals, and

cosmetics industries. The rising demand for zinc oxide nanoparticles is

 Technological Institute of the Philippines

expected to provide ample growth opportunities to the market over the forecast

period. The value chain of the market includes raw material suppliers,

manufacturers, distributors, and end users. The raw materials required for the

production of zinc oxide by the direct process are zinc chloride and sulfuric

acid. The aforementioned raw materials are supplied by various companies

present in the market including Pan-Continental Chemical Co., Flaurea

Chemicals, Zaclon LLC, BASF SE, INEOS, and others.

Figure 2. Global Market Size of Diisopropyl Ether

      (Source: Eternity Insights Report)

Geographically, the market is categorized in to five regions as North

America, Europe, Asia Pacific, Latin America, and the Middle East and Africa.

North America region dominates the global Diisopropyl Ether market in terms

of demand generation. The Diisopropyl Ether market in Asia Pacific region is

 Technological Institute of the Philippines

expected to grow at significantly high growth rate. The regional market is

further sub-segmented and analyzed at granular level across key countries. The

report will include market size and forecast for Diisopropyl Ether market for

below listed countries across each region.

North America (U.S. and Canada), Europe (Germany, France, Italy, UK, Spain,

and Rest of Europe), Asia Pacific (China, India, Japan, Australia, and Rest of

Asia Pacific region); Latin America (Brazil, Mexico, and rest of the Latin

America); Middle East and Africa (GCC, South Africa, and Rest of the Middle

East and Africa).

Figure 3. Global Market Size of Sulfuric Acid

    (Source: Research and Market)

 Technological Institute of the Philippines

This report provides an updated review of the sulfuric acid market, focusing on

its raw material type and application segments.  Global market size and

forecasts of the sulfuric acid market will be provided in terms of volume

(thousand tons) and value ($ million) from 2022 to 2027. COVID-19's impact

on the global market size will be considered while estimating the market size.

The report will also provide a detailed analysis of the regions, countries and

manufacturers. The global sulfuric acid market is expected to grow at a steady

pace from 2022 to 2027. Based on raw material type, the market is segmented

into elemental sulfur, base metal smelters, pyrite ore and others. North

America, Europe, Asia-Pacific CIS, Latin America, and Middle East and Africa

dominate the global market. Sulfuric acid finds major applicability in phosphate

fertilizers. Based on raw material type, the global sulfuric acid market is

segmented into elemental sulfur, base metal smelters, pyrite ore and others. 

Figure 4. Global Market Size of Glycerol 

(Source: Maximize Market Research)

 Technological Institute of the Philippines

The Global Glycerol Market is expected to reach XX Bn by 2026, at a CAGR

of XX% during a forecast period. Increasing adoption of biofuels and

augmented demand for oleochemicals are projected to drive the global glycerol

market. Glycerol products are extensively used in personal care products owing

to its property of interim as humectants and solvents. The report includes the

analysis of impact of COVID-19 lock-down on the revenue of market leaders,

followers, and disrupters. On the other hand, the growing price trends in

vegetable oil and fatty alcohols are expected to limit the growth of the market.

On the other hand, the growing price trends in vegetable oil and fatty alcohols

are expected to limit the growth in the global glycerol market.  The Asia Pacific

region is projected to be leading region in the global glycerol market. Biodiesel

is expected to boost the market growth in the region. Humectants aid in

retentive water in the skin, which reduces water loss owing to evaporation. The

objective of the report is to present a comprehensive assessment of the market

and provide insights into the market.

 Technological Institute of the Philippines

Figure 5. Natural Zeolite

The global natural zeolites market size was estimated at USD 6.47 billion in 2017.

It is projected to witness a CAGR of 2.7% from 2017 to 2025. The construction

industry is the major application market for natural zeolites. However, the product

is expected to witness rapid growth, in terms of demand, from soil amendment and

water purification applications. The Asia Pacific dominated the global natural

zeolites market, accounting for 64.1% market volume share in 2017. The market in

emerging economies such as India is gaining momentum, especially in the soil

amendment application. Considering the importance and vastness of India’s

agricultural industry, natural zeolite manufacturers are extending their reach in the

country.

In terms of revenue, the Central and South American market is anticipated to

progress at a CAGR of 2.6% over the forecast period. The demand for the product

is prevalent in Central and South America owing to the increasing soil and water

contamination and animal feed production. The region had over 4,287 mills for
 Technological Institute of the Philippines

feed production, as of 2016, and due to the increasing urbanization, the region is in

immediate need of water treatment projects as well.

VIII. SAFETY

A. Toxicological Rating 

In industrial process and manufacturing, the material handling safety is

frequently important and considered. The toxic effects of raw samples was

determined related to its potential health to humans and the basis in achieving

the toxicity level is acquired from the Material Safety Data Sheet of every raw

material throughout the process.

Table 13. Basis for Determining Raw Material Toxicity 

Criteria Raw Materials

Zinc Diisoprop Sulfuric Glycerol Natural

Oxide yl ether Acid Zeolite

The severity No data Prolonged No data Based on No data

of Immediate available  or available  available availabl
Effects repeated data, the e 
skin classificati
contact on criteria
may cause are not
drying met.
and
cracking
of the
exposed
areas

Sensitization No data No data No data Based on No data

Level available  available  available  available availabl
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data, the e
classificati
on criteria
are not met

Carcinogenici Not No data Not known Based on Not

ty classifie available  to cause available classifie
d cancer. data, the d
Strong classificati
inorganic on criteria
mists are not met
containing and no
sulfuric acid known
are carcinogeni
carcinogenic c
to humans chemicals.

Reproduce No data No data Not known Based on No data

Toxicity available available  to be a available availabl
Level reproductive data, the e
hazard. classificati
on criteria
are not met

The Severity Not No data Can cause No No data

of Chronic Availabl available  dry, red, informatio availabl
Effects  e  cracked skin n available. e 
(dermatitis)
following
skin contact.
At high
concentratio
ns: May
wear away
tooth enamel
when
breathed in.
May harm
the
respiratory
system. Can
irritate and
 Technological Institute of the Philippines

inflame the
airways.

Table 14. Basis of Environmental Hazard Level for the Raw Materials

Criteria Raw Materials

Zinc Diisoprop Sulfuric Acid Glycerol Natural

Oxide yl ether Zeolite

Aquatic Highly Not Not Low toxicity Toxicit

Toxicity toxic to classified determined to aquatic y to
aquatic as organisms fish 
organism hazardous
s

Toxicity No data No data It has Low toxicity Acute

on Plants available available moderate to animals toxicity
and chronic and plants  to
Animals  (long-term) animals
toxicity to such as
aquatic life. rabbits
Chronic and
effects on green
plants, birds algae.
or land
animals have
not been
determined

Toxicity of Not Not Hazardous 60% Not

Immediate classified classified decompositio biodegradatio known. 
Degradatio n products. n in 10 days
n (readily
biodegradabl
e)

Long-term Not Not Hazardous 92 % Not

Degradatio classified classified decompositio biodegradatio known.
n n products n after 30
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days (readily
biodegradabl
e)

Table 15. Health Hazard Rating 

RATING DESCRIPTION

0 For minimal hazard or no significant risk for health

1 For slight hazard or minor reversible injury possible

2 For moderate hazard, a temporary or minor inquiry may occur

3 For serious hazard, a major inquiry likely unless prompt action is

taken and medical treatment is given 

4 For severe hazard,  life-threatening major or permanent damage

may result from single or repeated exposures

Table 16. Toxicity Rating of Raw Materials 

(Source: MSDS)

Criteria Raw Materials

Weigh Zinc Diisopropyl Sulfuric Glycero Natural

t Oxide ether Acid l Zeolite

The severity of 0.05 0 2 0 1 0

Immediate
Effects

Sensitization 0.10 0 0 0 1 0
Level

Carcinogenicity 0.20 1 0 0 0 0

Reproduce 0.30 1 0 0 0 0
Toxicity Level
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The Severity of 0.35 0 0 2 0 0

Chronic Effects 

Subtotal 1 0.5 0.1 0.7 0.15 0

Total 1.45

Table 17. Environmental Hazard Level Rating  of Raw Materials

(Source: MSDS)

Criteria Raw Materials

Weight Zinc Diisopropyl Sulfuric Glycerol Natural

Oxide ether Acid Zeolite

Aquatic 0.35 3 0 0 1 1
Toxicity

Toxicity on 0.15 0 0 3 1 1
Plants and
Animals

Toxicity of 0.20 0 0 1 1 0
Immediate
Degradation

Long-term 0.30 0 0 1 2 0
Degradation

Subtotal 1 1.05 0 0.95 1.3 0.5

Total 3.8
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Table 18: Basis for Determining By-products Toxicity 

Criteria Raw Materials

Formic Acid Acetic Acid

The severity of Severe irritant of Severe eye irritation and skin

Immediate Effects the eyes, mucous burning. 
membranes, and
skin

Sensitization No data available  Rare but occurred

Level

Carcinogenicity Not classified No data available 

Reproduce No classified No data available 

Toxicity Level

The Severity of Not Available  Chronic exposure to acetic acid

Chronic Effects  may cause erosion of dental
enamel, bronchitis, eye irritation,
darkening of the skin, and chronic
inflammation of the respiratory
tract.

Table 19. Basis of Environmental Hazard Level for the By-products

Criteria Raw Materials

Formic Acid Acetic Acid

Aquatic Toxicity No data available   Not classified 

Toxicity on Plants and No data available  No data available 

Animals

Toxicity of Immediate Biodegradable Biodegradable

Degradation readily. readily
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Long-term Degradation No data available No data available 

Table 20. Toxicity Rating of By-products

Criteria Weigh Raw Materials

t
Formic Acid Acetic Acid

The severity of Immediate Effects 0.30 2 1

Sensitization Level 0.10 0 1

Carcinogenicity 0.15 0 0

Reproduce Toxicity Level 0.40 0 0

The Severity of Chronic Effects  0.15 0 2

Subtotal 0.6 0.7

Total 1.3

Table 21. Basis of Environmental Hazard Level for Scores for the By-products

Criteria Weight Raw Materials

Formic Acetic Acid

Acid

Aquatic Toxicity 0.3 0 0

Toxicity on Plants and Animals 0.1 0 0

Toxicity of Immediate 0.4 1 1

Degradation

Long-term Degradation 0.2 0 0

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Subtotal 0.4 0.4

Total 0.8

XII. ADVANTAGES AND DISADVANTAGES

A. Advantages/ Opportunities

 Alternative methods are used to produce fuels and chemicals in a more

sustainable manner.

 The cost of the equipment that will be used in this process is lower than

the cost of the equipment that will be used in the other two processes.

B. Disadvantages/ Issues

 Direct Esterification process produces highly polluted aqueous liquors

that cannot be discharged without prior treatment. The treatment design

is technically expensive.

 The handling of products and raw materials throughout the process may

be challenging and dangerous, compromising product quality,

productivity, and process safety.