ABS from Butadiene, Acrylonitrile and Styrene (Emulsion Process)
Acrylonitrile Butadiene Styrene Production Costs Report | Issue A | Q3 2024
| Report Details |
| 150 kta United States-based plant | Q3 2024 | 107 pages |
This report presents a cost analysis of a 150 kta (kilo metric ton per annum) United States-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.
Report Abstract
This report presents the economics of Acrylonitrile Butadiene Styrene (ABS) polymer production in the United States using an emulsion process. In this process, butadiene is first polymerized in the presence of water, forming a latex. The polybutadiene latex is submitted to a grafting reaction with styrene and acrylonitrile monomers. The graft latex is mixed with a SAN Latex produced separately.
The report provides a comprehensive study of Acrylonitrile Butadiene Styrene production and related Acrylonitrile Butadiene Styrene production cost, covering three key aspects: a complete description of the Acrylonitrile Butadiene Styrene production process examined; an in-depth analysis of the related Acrylonitrile Butadiene Styrene plant capital cost (Capex); and an evaluation of the respective Acrylonitrile Butadiene Styrene plant operating costs (Opex).
The Acrylonitrile Butadiene Styrene production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The Acrylonitrile Butadiene Styrene plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The Acrylonitrile Butadiene Styrene plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Process Schematic
The process under analysis comprises four major sections: (1) Polybutadiene polymerization; (2) Grafting; (3) SAN Resin Polymer production; and (4) Rubber finishing.
Polybutadiene polymerization. In this area, the butadiene is polymerized to polybutadiene by an emulsion polymerization process, carried out in continuously stirred jacketed tank reactors connected in series. The latex is directed to a stirred vessel, where unconverted butadiene is stirred out from the latex and fed back to reactor. Part of the polybutadiene latex particles are still submitted to a chemical/physical agglomeration step.
Grafting. Styrene and acrylonitrile are mixed in adequate proportion. Then, they are grafted onto polybutadiene latex by emulsion polymerization in a continuous stirred tank reactor. After the end of the reaction, the grafted rubber is subsequently steam stripped for the removal of residual monomers.
SAN Resin Polymer production. At the same time of the steps described above, styrene and acrylonitrile are mixed in adequate proportion for the production of resin. SAN production is carried out in two emulsion polymerization steps, in which those monomers are dispersed in water also using emulsifier. Both polymerization steps take place in stirred tank reactors. The polymer slurry is cooled and fed to the top of a vacuum plate column, where residual monomers are steam stripped and recycled.
Rubber finishing. The SAN resin is added as a stabilizer system to the grafted rubber latex, to protect it from oxidation during subsequent powder drying and compounding. ABS graft rubber is isolated from the polymer latex after deactivation of the emulsifiers. Finally, after dewatering, drying and extrusion steps, ABS pellets are obtained.
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Production Process Information
Process Consumptions
Labor Requirements
Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
Plant Capital Cost Details
Operating Cost Details
Plant Cost Breakdowns
Plant Capacity Assessment
Process Flow Diagrams
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Acrylonitrile Butadiene Styrene production plant examined
Plant Capital Cost Details
Detailing of fixed capital (ISBL, OSBL & Owner’s Cost), working capital and additional capital requirements
Plant Cost Breakdowns
Breakdown of Acrylonitrile Butadiene Styrene process unit (ISBL) costs and infrastructure (OSBL) costs; plant cost breakdown per discipline
Operating Costs Summary
Summary presenting the operating variable costs and the total operating cost of the Acrylonitrile Butadiene Styrene production plant studied
Operating Cost Details
Detailing of utilities costs, operating fixed costs and depreciation
Plant Capacity Assessment
Comparative analysis of capital investment and operating costs for different Acrylonitrile Butadiene Styrene plant capacities
Production Process Information
Block Flow Diagram, descriptions of process unit (ISBL) and site infrastructure (OSBL)
Process Consumptions
Raw materials and utilities consumption figures, by-products credits, labor requirements
Process Diagrams
Process flow diagrams (PFD), equipment list and industrial site configuration
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