ABS from Butadiene, Acrylonitrile and Styrene (Hybrid Process)
Acrylonitrile Butadiene Styrene Production Costs Report | Issue C | Q2 2024
Report Details |
120 kta United States-based plant | Q2 2024 | 107 pages | Delivered in PDF |
This report presents a cost analysis of a 120 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
In this report, the process examined for the Acrylonitrile Butadiene Styrene (ABS) production is a hybrid polymerization process in the United States. Initially, a solution of styrene and acrylonitrile is bulk prepolymerized with agitation. Polymerization is further conducted in suspension in water.
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 Overview
Product
Acrylonitrile Butadiene Styrene. Acrylonitrile Butadiene Styrene (a.k.a. ABS) is the largest selling engineering thermoplastic worldwide. ABS consists of a family of polybutadiene resin grafted with acrylonitrile and styrene. Property advantages from this polymer includes good processability, chemical resistance and thoughness. These properties can be optimized by adjusting the ratio of the three monomers which allows for incredible versatility to meet product requirements. While the polymer components coexist as two separate phases, ABS actually represents one of the industrially most important thermoplastic two-phase systems with an amorphous structure.
Raw Materials
Butadiene. Butadiene is a commodity mainly produced as a byproduct of ethylene crackers. More specifically, it is extracted from the C4 hydrocarbons stream in naphtha-based crackers. The largest single use of butadiene is in the production of SBR and styrene-butadiene latexes.
Styrene. Styrene is a largely available commodity generally produced from ethylbenzene by several means. One of the commercial routes for styrene production relies on the alkylation of benzene with ethylene for generating the ethylbenzene, which is then dehydrogenated to styrene in vapor phase with steam.
Acrylonitrile. Acrylonitrile is a molecule having a carbon-carbon double bond conjugated with a nitrile group. It is a very reactive compound, since it is polar (due to the presence of the nitrogen heteroatom) and unsaturated. Currently, acrylonitrile is mainly produced by the ammoxidation of propylene and by the ammoxidation of propane. Both processes generate acetonitrile and hydrogen cyanide as by-products. As a highly reactive chemical, acrylonitrile serves as an intermediate to produce a range of chemicals, including antioxidants, pharmaceuticals and especially polymers. Due to the possibility of spontaneous polymerization in the presence of strong alkali or when exposed to light, high-purity acrylonitrile product must be stored or transported with polymerization inhibitors. Storage tanks or containers may be constructed with carbon or stainless steel.
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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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