Oxalyl Chloride Manufacturing Plant Project Report 2025

The report is the result of extensive primary and secondary research, offering a detailed analysis of current market trends. It profiles key industry players, giving insights into their market strategies, production capacities, and financial performance, which are crucial for benchmarking and competitive analysis.

It delves into historical, current, and forecasted price trends, helping stakeholders understand market dynamics and price volatility. The report provides a thorough analysis of the mass balance and raw materials requirements, ensuring a clear understanding of the input-output ratios essential for efficient production. Detailed examinations of the various unit operations integral to the oxalyl chloride manufacturing process are included, highlighting process optimisation techniques and technological advancements.

The report presents a comprehensive capital cost analysis, detailing the financial investment required for setting up an oxalyl chloride plant. This includes an exhaustive breakdown of costs associated with raw materials, catchem, utilities, labour, packaging, transportation, land acquisition, construction, and machinery. Additionally, it offers an in-depth look at the operating costs, providing clarity on the recurring expenses involved in running the plant.

Projected profit margins and optimal product pricing strategies are outlined, offering guidance on maximising profitability. The report also addresses regulatory frameworks, environmental impacts, and sustainability measures pertinent to the oxalyl chloride industry.

About Oxalyl Chloride

Oxalyl chloride (Cl-C(=O)-C(=O)-Cl) is a highly reactive and versatile organic reagent used in various synthetic transformations. It was first prepared in 1892 by French chemist Adrien Fauconnier through the reaction of diethyl oxalate and phosphorus pentachloride. Oxalyl chloride is commonly used for the preparation of acyl chlorides from carboxylic acids, the Swern oxidation of alcohols to aldehydes and ketones, and other organic reactions like chlorination, formylation, and esterification. However, it is a toxic substance that must be handled with care.

Properties of Oxalyl Chloride

Oxalyl chloride is a colourless, sharp-smelling liquid that is the diacyl chloride of oxalic acid. It has a melting point of -16°C and a boiling point of 140°C. Oxalyl chloride is a highly reactive compound that violently reacts with water, producing hydrogen chloride, carbon dioxide, and carbon monoxide. It has a density of 1.488 g/mL and a refractive index of 1.4340. These properties make oxalyl chloride a useful reagent in several organic synthesis.

Manufacturing Process of Oxalyl Chloride

The production of oxalyl chloride involves a multi-step process. The first stage is the chlorination of ethylene carbonate to form tetrachloroethylene carbonate. This is typically achieved through a photochemical chlorination reaction. The tetrachloroethylene carbonate is then heated within a temperature range of 35-130°C, which triggers the decomposition of the compound and the subsequent formation of oxalyl chloride.

Alternatively, a similar decomposition process can be employed using a tetrachloroethylene glycol ester containing only carbon, oxygen, and chlorine. In this case, the ester is heated to a temperature between 60-80°C in the presence of a catalyst, such as activated charcoal, tertiary amines, amides of secondary amines, tertiary phosphines, or tertiary arsines. This catalytic heating also leads to the production of oxalyl chloride.

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Synthesis of Oxalyl Chloride

The industrial process of making oxalyl chloride involves the chlorination of oxalic acid or its derivatives. Below is a detailed description of the process:

1.    Raw Materials

The primary raw materials used in the production of oxalyl chloride include:

• Oxalic acid (C₂H₂O₄)

• Thionyl chloride (SOCl₂)

• Phosphorus pentachloride (PCl₅) or phosphorus trichloride (PCl₃) as chlorinating agents

2.    Chlorination of Oxalic Acid

• Oxalic acid is first reacted with thionyl chloride to produce oxalyl chloride and sulfur dioxide: C₂H₂O₄ + 2SOCl₂ → (COCl)₂ + 2SO₂ + 2HCl

• Alternatively, oxalic acid can be reacted with phosphorus pentachloride to produce oxalyl chloride and phosphorus oxychloride: C₂H₂O₄ + PCl₅ → (COCl)₂ + POCl₃ + H₂O

• Another method involves the reaction of oxalic acid with phosphorus trichloride and chlorine gas: C₂H₂O₄ + 2PCl₃ + Cl₂ → (COCl)₂ + 2POCl₃ + 2HCl

3.    Purification

• The crude oxalyl chloride produced in the chlorination step is purified by distillation to remove any unreacted starting materials and by-products.

• The purified oxalyl chloride is collected as a colorless liquid with a pungent odor.

4. Handling and Safety

• Oxalyl chloride is highly reactive and should be handled with care.

• Proper safety measures, including the use of personal protective equipment (PPE) and adequate ventilation, should be in place to prevent exposure to toxic fumes.

• Oxalyl chloride should be stored in airtight containers to prevent moisture ingress, which can lead to hydrolysis and the release of hydrogen chloride gas.

Applications and Drivers of Oxalyl Chloride

Oxalyl chloride is primarily used for the preparation of acid chlorides from carboxylic acids, a key step in various chemical transformations. Oxalyl chloride also finds use in the formylation of aromatic compounds through Friedel-Crafts acylation, as well as in the synthesis of diesters from alcohols. One of its most important applications is in the Swern oxidation, where it is combined with dimethyl sulfoxide (DMSO) to convert alcohols into aldehydes and ketones. The high reactivity and versatility of oxalyl chloride make it an indispensable reagent in organic chemistry, driving its demand in the synthesis of a wide range of chemical compounds.

Key Features of the Oxalyl Chloride Production Cost Report:

This production cost analysis report by Expert Market Research scrutinises the oxalyl chloride manufacturing process, offering a comprehensive overview necessary for stakeholders considering venturing into this sector. Based on the latest economic data, the report encompasses detailed insights into the primary process flow, raw material requirements, reactions involved, utility costs, operating costs, capital investments, pricing strategies, and profit margins. This report is an indispensable resource for entrepreneurs, investors, researchers, consultants, business strategists, and all those who have any kind of stake in the oxalyl chloride industry. It equips them with essential information and strategic insights to effectively navigate the complexities of the market.

The following sections detail the comprehensive scope of the prefeasibility report for an oxalyl chloride production plant:

• Market Dynamics and Trends: This section analyses the prevailing market conditions, growth drivers, and trends impacting the oxalyl chloride industry. It offers a thorough examination of demand fluctuations and projections.

• Geographic Analysis: Detailed insights into the major regions active in oxalyl chloride production and consumption, highlighting regional market specifics and growth potential.

• Key Industry Players: Profiles of leading manufacturers in the oxalyl chloride sector, outlining their market share, strategic positions, and operational strengths.

• Price Fluctuations: Analysis of historical, current, and projected price trends, providing stakeholders with essential pricing intelligence.

• Technical Specifications and Process Description: A detailed overview of the oxalyl chloride production process including the technology used and innovations within the industry.

• Raw Material Requirements and Sourcing: Evaluation of necessary raw materials, their sourcing strategies, and cost implications.

• Utility Requirements and Costs: Detailed analysis of utilities needed to produce oxalyl chloride, such as electricity, steam, and process water along with their cost assessments. 

• Labour Force Dynamics: Insights into manpower requirements, including skill specifications and labour cost projections.

• Packaging Needs: Overview of packaging requirements for oxalyl chloride to ensure product integrity and cost efficiency.

• Logistics and Transportation: Examination of transportation needs and logistics planning for distribution and supply chain efficiency.

• Capital and Operating Costs: An in-depth look at investment requirements, including land acquisition and its development cost, civil work costs, construction, machinery procurement, and ongoing operational expenses, such as salaries and wages, plant overheads, tax and insurance as well as packaging, transportation, and administration costs.

• Financial Performance and Profitability Analysis: Projected profit margins and return on investment based on current market and operational parameters.

• Product Pricing Strategy: Recommendations on pricing mechanisms based on industry benchmarks and production costs.

• Environmental Impact and Regulatory Compliance: Analysis of environmental considerations and compliance with local and international regulations.

• Risk Assessment and Mitigation Strategies: Identification of potential risks associated with oxalyl chloride production and strategies to mitigate them.

Key Questions Addressed:

• What are the detailed unit operations for oxalyl chloride production?

• Who are major technology licensors with their process evaluation?

• How are raw materials or catchem procured and what are their cost implications?

• What utilities are essential for production and what will they cost?

• What are the labour requirements and how does this affect operational costs?

• What packaging solutions are optimal for cost and efficiency?

• What logistical arrangements are necessary for efficient product distribution?

• What are the estimated land and construction costs for a new oxalyl chloride plant?

• How can profitability be maximised in the oxalyl chloride market?

• What pricing strategy should be adopted for oxalyl chloride to remain competitive?

This prefeasibility report aims to equip potential investors and existing manufacturers with crucial insights to make informed decisions in the oxalyl chloride industry.