What is a acrylates project report?
An acrylates project report is a detailed project report (DPR) for a plant that reacts acrylic acid with alcohols to make acrylic ester monomers such as n-butyl acrylate and 2-ethylhexyl acrylate. It sets out the process, equipment, raw materials, approvals, project cost, means of finance, five-year projections, DSCR and break-even.
Chemical entrepreneurs and emulsion makers planning backward integration use it to size the plant and raise a term loan; lenders use it to judge whether the thin conversion margin can service debt.
Also known as: acrylic esters project report, butyl acrylate plant project report, acrylic monomer plant DPR, acrylates business plan.
Acrylates plant cost in India: what the sample project shows
Our sample report models a 6.3 metric tonnes per day esterification plant, or 2,079 MT per year, running 330 days a year. It starts at 60% of capacity and reaches 80% in Year 5, selling at ₹1,37,000 per MT.
The plant buys acrylic acid rather than making it. That keeps plant and machinery at ₹347 lakh. It also means raw materials take about 59.5% of sales, so the margin rests on the spread between the ester and its feedstocks.
| Land and site development | 71.08 |
|---|---|
| Building and civil works | 181.26 |
| Plant and machinery | 347.24 |
| Other fixed assets | 43.61 |
| Contingencies | 26.42 |
| Preliminary and pre-operative | 16.74 |
| Working capital margin | 67.66 |
| Total | 754.01 |
| Promoter's contribution (25%) | 188.50 |
|---|---|
| Term loan from bank (75%) | 565.51 |
| Cash credit limit (separate) | 202.96 |
| Total project cost | 754.01 |
Term loan at 10.5% with a 6-month moratorium and 54 monthly instalments; lowest yearly DSCR 1.49. All figures are illustrative.
Acrylates manufacturing process, step by step
Acrylic esters are made by acid-catalysed esterification of acrylic acid with an alcohol: n-butanol gives butyl acrylate and 2-ethylhexanol gives 2-EHA. The chemistry is simple; the skill lies in stopping the monomer from polymerising inside hot equipment.
- Charging
Acrylic acid, a small excess of alcohol, the acid catalyst and a polymerisation inhibitor go into a stainless steel reactor.
- Esterification with water removal
The batch is heated and the water formed is taken off continuously through a reflux column, which pushes the equilibrium towards the ester.
- Neutralising and washing
The crude ester is washed with dilute caustic soda and water to strip out unreacted acrylic acid and catalyst.
- Alcohol recovery
Excess butanol or 2-ethylhexanol is distilled off and recycled, which decides how much alcohol each tonne really consumes.
- Vacuum distillation
The ester is distilled under vacuum so that column temperatures stay low, separating it from heavy residues to monomer purity.
- Inhibiting, testing and storage
MEHQ is dosed, purity is checked by gas chromatography, and the monomer is held cool under a lean-air pad before filling drums or tankers.
Which acrylates process route suits a new plant?
There are two ways into acrylates. An integrated producer oxidises propylene to acrylic acid and esterifies it on the same site; a standalone unit buys acrylic acid and only runs the esterification and purification steps.
| Point to compare | Buy acrylic acid and esterify | Integrated propylene route |
|---|---|---|
| Main feedstock | Acrylic acid and n-butanol or 2-ethylhexanol | Polymer-grade propylene and oxo-alcohols |
| Typical scale | A few thousand MT per year | Hundreds of thousands of MT per year across products |
| Investment | Within MSME and mid-size term lending | Refinery-linked petrochemical project |
| Main risk | Feedstock price and supply; thin spread | Scale, technology licence and propylene cost |
| Catalyst options | Sulphuric acid, p-toluene sulphonic acid or cation-exchange resin | Licensor's catalyst system |
Catalyst choice changes the effluent: a homogeneous acid such as p-toluene sulphonic acid has to be washed out and neutralised. A fixed-bed cation-exchange resin stays in the reactor and cuts the salt load on the effluent plant, at a higher first cost.
Raw materials for butyl acrylate and 2-EHA
Glacial acrylic acid is the largest cost. It freezes at about 13°C and slowly forms dimer in storage, so it is held in heated, inhibited tanks and bought in lots the plant can use within weeks.
| Raw material | Share of cost | Year 3 (₹ lakh) |
|---|---|---|
| Glacial acrylic acid | 55% | 652.61 |
| n-Butanol | 30% | 355.97 |
| 2-Ethylhexanol | 10% | 118.66 |
| Catalyst and polymerisation inhibitors | 3% | 35.60 |
| Caustic soda for neutralisation | 2% | 23.73 |
| Total | 100% | 1,186.57 |
Year 3 at 70% utilisation, from our illustrative sample. Packing drums are costed separately.
Machinery for an acrylic ester plant
Wetted parts are stainless steel, since acrylic acid corrodes carbon steel and iron traces can start polymerisation. The vacuum distillation columns are the costliest item in the sample.
| Equipment | What it does | Sample cost (₹ lakh) |
|---|---|---|
| Esterification reactor with reflux column | Reacts acid and alcohol, removes water | 76.39 |
| Vacuum distillation columns | Recover alcohol and purify the ester | 83.34 |
| Neutralisation and wash system with decanters | Removes leftover acid and catalyst | 27.78 |
| Heat exchangers, condensers and vacuum system | Heat, condense and hold column vacuum | 41.67 |
| Storage tanks with lean-air padding and chilling | Keep acid and monomer stable | 48.61 |
| Thermic fluid heater, chiller and cooling tower | Supply heating and cooling duty | 34.72 |
| Effluent treatment plant | Treats wash water before discharge | 20.84 |
| Quality control laboratory with gas chromatograph | Tests purity, acidity and inhibitor level | 13.89 |
| Total plant and machinery | 347.24 | |
Costs are the sample report's estimates for a 6.3 MT per day plant. Get current quotations before you finalise.
Utilities and manpower for an acrylates unit
Distillation makes this a heat-hungry plant: reboilers need steady thermal input while condensers and monomer storage need chilled water.
| Power and fuel | ₹155.83 lakh in Year 3 in our sample, about 7.8% of sales |
|---|---|
| Heating | Thermic fluid heater for reactor and column reboilers |
| Cooling | Cooling tower for condensers, chiller for vent condensers and cool storage |
| Water | Process water for washing and catalyst extraction, plus cooling tower make-up |
| Manpower | 45 people in the sample, Year 1 cost ₹102.30 lakh, with shift operators for continuous running |
Licences and approvals for an acrylates plant
Acrylic esters are flammable, reactive monomers made in an organic chemicals plant, so approvals take longer than for most MSME units. Start them while the plant design is being frozen.
| Pollution board consent | Consent to establish and operate; organic chemicals manufacturing is in the Red category, as of October 2026 |
|---|---|
| BIS quality control order | n-Butyl acrylate falls under the 2021 order requiring IS 14709 and the BIS mark; its operation was suspended in 2026, last notified until 31 July 2026. The methyl and ethyl acrylate order was rescinded on 28 November 2025 |
| Hazardous chemicals | Manufacture, Storage and Import of Hazardous Chemical Rules, 1989; n-butanol is a listed chemical, and flammable liquids above threshold quantities bring safety reports and on-site emergency plans |
| Factory and fire | Factory licence under the Factories Act and fire NOC for solvent and monomer storage; rules vary by state |
| Business registration | Udyam (MSME) registration where the unit qualifies, and GST registration |
Rules change. Confirm the current BIS and pollution board position for your state before you apply.
Market for acrylates in India
Demand follows the makers of acrylic emulsions, who turn butyl acrylate and 2-EHA into binders for paints, tape adhesives, textile finishes and construction chemicals. Decorative paint and packaging tape growth carry most of the volume.
On the supply side, BPCL's propylene derivative complex, dedicated in February 2021, makes acrylic acid, butyl acrylate and 2-EHA within a 329 KTPA product slate. The rest of the market is served by imports, and in 2026 the government suspended the butyl acrylate quality order to keep supply available during a global disruption.
- Acrylic emulsion and polymer makers
- Paint and coating manufacturers
- Pressure-sensitive adhesive and tape makers
- Textile and leather chemical makers
- Construction chemical producers
- Chemical traders and distributors
Where a smaller unit wins: emulsion makers want fresh, correctly inhibited monomer delivered on time in drums or part loads. A plant within a day's drive of an emulsion cluster can offer that against imported cargo.
Mistakes that weaken an acrylates project report
- Modelling a fixed margin
The ester price and acrylic acid price move together but not equally. A report that holds the spread steady for five years overstates DSCR; test a narrower spread.
- Ignoring polymer fouling downtime
Popcorn polymer builds up in reboilers and column trays. Plan cleaning shutdowns and inhibitor dosing, or the utilisation curve is too optimistic.
- Storing monomer under pure nitrogen
MEHQ needs dissolved oxygen to work. Tanks are padded with lean air, and the layout and safety budget must show it.
- Sizing the effluent plant for water only
Wash water carries acrylate salts, alcohol and catalyst with high COD. An undersized plant delays Red category consent.
- Assuming full alcohol recovery
Some butanol is lost in wash water and vents. Use realistic consumption per tonne of ester, not the textbook ratio.
How NPCS helps you plan an acrylates plant
- Product mix and capacityDecide between butyl acrylate, 2-EHA or both, and size the plant to your buyers.
- Route and equipmentCompare catalyst options, column design and equipment suppliers, with quotations.
- Bank-ready project reportProjections, DSCR, spread sensitivity and working capital in the format your lender uses.
- Approvals and layoutPlant layout, storage safety and the approvals list for your state, including BIS status.
NPCS has prepared project reports and feasibility studies for chemical plants since 1994, and its published client list includes 269 specialty chemicals assignments, one of them for acrylates.
What's inside the acrylates sample report
- Introduction
- Uses and applications
- Market potential
- Manufacturing process
- Raw materials
- Plant and machinery
- Land, building and utilities
- Manpower
- Licences and approvals
- Project cost and means of finance
- Working capital
- Projected profitability
- Cash flow statement
- Projected balance sheet
- Depreciation
- Term loan repayment
- Debt service coverage
- Break-even analysis
- Financial ratios
- Key assumptions
- Conclusion
- Monthly loan repayment schedule
18 pages, five-year projections, illustrative figures.
Open sample reportFree sample or a report for your project?
| What you get | Free sample | NPCS report for your project |
|---|---|---|
| Capacity and location | Typical unit | Your capacity, site and state |
| Figures | Illustrative | Built on current prices and quotations |
| Machinery suppliers and quotations | No | Yes |
| Market survey for your region | No | Yes |
| Bank or scheme format (PMEGP, term loan) | No | Yes |
| Use for a loan application | No | Yes |
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Acrylates project report: frequently asked questions
What is the acrylates manufacturing plant cost in India?
An esterification unit that buys acrylic acid needs roughly ₹3–5 crore for 2–3 MT per day and ₹6–12 crore for 5–10 MT per day. Both ranges include land, building and working capital margin. Our sample report models a 6.3 MT per day plant at ₹754 lakh. These are indicative figures; your report prices equipment, site and approvals for your own case.
What raw materials are used to make butyl acrylate?
Butyl acrylate is made from acrylic acid and n-butanol, with an acid catalyst and a polymerisation inhibitor such as MEHQ. In our sample report acrylic acid is 55% of raw material cost and n-butanol 30%, with 2-ethylhexanol for 2-EHA, catalyst, inhibitors and caustic soda making up the rest. Raw materials come to about 59.5% of sales.
Which acrylates can one plant make?
The same esterification and vacuum distillation train can make n-butyl acrylate and 2-ethylhexyl acrylate by switching the alcohol, run in campaigns. Methyl and ethyl acrylate use methanol or ethanol and need different column conditions, because these esters boil lower and form azeotropes with water. Most mid-size units settle on butyl acrylate first, as emulsion makers buy it in the largest volumes.
Is BIS certification mandatory for butyl acrylate?
n-Butyl acrylate is covered by the n-Butyl Acrylate (Quality Control) Order, 2021, which calls for IS 14709 and the BIS mark. Its operation was suspended in 2026, most recently until 31 July 2026 by S.O. 3729(E). The order for methyl and ethyl acrylate was rescinded on 28 November 2025. Check the current BIS position before planning sales.
Is acrylates manufacturing profitable?
In our illustrative sample, a 6.3 MT per day plant reaches a 20% return on investment in Year 3. Break-even is at 42% of capacity and payback takes about 3.8 years. Profit depends mostly on the spread between the ester price and acrylic acid and alcohol costs, so the report should test how that spread narrows.
What are acrylates used for?
Acrylates are mainly used to make water-based acrylic emulsions for paints, pressure-sensitive adhesives and tapes, textile and leather finishing binders, paper coatings and construction chemicals. Butyl acrylate gives soft, flexible films with good weathering, while 2-ethylhexyl acrylate is the main monomer in acrylic tape adhesives. Both are copolymerised with other monomers such as styrene or vinyl acetate.
Is the acrylates project report PDF sample free, and can I use it for a loan?
The sample is free to view and download. It is an illustrative report that shows the format and depth of an NPCS report. Its figures are representative and not based on a real project, so it should not be submitted to a bank. For a loan, NPCS prepares a report for your own capacity, location and product mix.
Sources and references
- n-Butyl Acrylate (Quality Control) Order, 2021: amendment S.O. 1854(E), 10 April 2026Bureau of Indian Standards (Department of Chemicals and Petrochemicals notification), checked Oct 2026
- S.O. 3729(E), 9 July 2026: suspension of the n-Butyl Acrylate QCO extended to 31 July 2026Gazette of India, Ministry of Chemicals and Fertilizers, checked Oct 2026
- Rescission of quality control orders for six chemicals, including Methyl Acrylate and Ethyl Acrylate (S.O. 5529(E), 28 November 2025)Department of Chemicals and Petrochemicals, checked Oct 2026
- Red, Orange, Green and White category list (Red: organic chemicals manufacturing)State Pollution Control Board, Odisha, checked Oct 2026
- Manufacture, Storage and Import of Hazardous Chemical (Amendment) Rules, 2000Ministry of Environment and Forests, via FAOLEX, checked Oct 2026
- Petrochemicals: propylene derivative petrochemical complexBharat Petroleum Corporation Limited, checked Oct 2026
- Butyl acrylate and 2-ethylhexyl acrylate product pagesBharat Petroleum Corporation Limited, checked Oct 2026
- 2-Ethylhexyl acrylate monograph (production, inhibitors, uses)International Agency for Research on Cancer (WHO), checked Oct 2026
The NPCS project team, led by Ajay Kumar Gupta
This page and its sample report are prepared and reviewed by the NPCS project team, which has written techno-economic feasibility studies and detailed project reports since 1994.
Ajay Kumar Gupta founded Niir Project Consultancy Services (NPCS) and leads the organisation. With 40 years of experience in MSME project consulting, he has built the team that has delivered more than 28,000 project reports for clients worldwide, helping entrepreneurs plan and finance profitable manufacturing businesses.
- Published
- Last updated
- Next review
- Oct 2027
- Reviewed by
- NPCS project team
This page is reviewed every 12 months, or sooner when scheme limits, GST rates, BIS rules or pollution categories change. The sample report is illustrative: its figures are generated from industry-typical ratios for a unit of this size, checked so every statement balances, and are not taken from any client project.