Integrated Process Simulation and Feasibility Assessment of a Butyl Acrylate Manufacturing Plant from Acrylic Acid and n-Butanol in the Philippines

The rising global demand for Acrylates driven by applications in paints, adhesives, textiles, and plastics has heightened the need for sustainable and economically viable production methods. Butyl acrylate, a key acrylate ester, is typically synthesized through the esterification of acrylic acid and n-butanol using homogeneous acid catalysts. However, these catalysts pose challenges related to corrosiveness, product separation, and environmental impact. This study presents the integrated process simulation and techno-economic assessment of a full scale butyl acrylate manufacturing plant in the Philippines utilizing heterogeneous catalysis. The process was modelled using Aspen HYSYS V11 software and included plantwide control strategies. Catalyst and site selection were supported through multi-criteria decision-making via Visual PROMETHEE. The proposed facility is designed to produce 31,328 metric tons per year of high-purity (99.99 %) butyl acrylate, with export targets including India, Vietnam, and Thailand, alongside domestic distribution. Economic analysis yields a projected return on investment (ROI) of 60.84 % and a payback period of 5.11 years, confirming the technical and financial viability of establishing local production and supporting the Philippines’ entry into the regional butyl acrylate market.