ABS from Polybutadiene, Acrylonitrile and Styrene (Mass Process)
Acrylonitrile Butadiene Styrene Production Costs Report | Issue B | Q3 2024
| Report Details |
| 120 kta United States-based plant | Q3 2024 | 107 pages |
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
This report assesses the economics of an industrial plant in the United States for the production of Acrylonitrile Butadiene Styrene (ABS) via a mass polymerization process. Initially, butadiene rubber is ground in a mill and dissolved in acrylonitrile and styrene. The mixture is submitted to a two-step copolymerization in the presence of a solvent.
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 three major sections: (1) Pre-polymerization; (2) Polymerization; and (3) Finishing.
Pre-polymerization. Polybutadiene rubber, in bale form, is ground in a mill and fed along with fresh styrene and acrylonitrile to a high-shear mixer. The rubber solution prepared is sent to a surge tank before being routed to the Pre-polymerization reactor. Monomers and ethylbenzene recovered downstream are added to the reactor and pre-polymerization is carried out to a 15-30% conversion of styrene.
Polymerization. The pre-polymerization product is sent to the polymerization reactors, where the polymerization is continued. The resulting polymer slurry is directed to a set of two flash tanks in series, in which light components are removed from the polymer solution and routed to a distillation column. The column overhead, rich in styrene and acrylonitrile, is recycled to the pre-polymerization reactor, while heavy components withdrawn from the bottom is discarded. The polymer solution from Devolatilization is directed to next section.
Finishing. The polymer melt is filtered and fed to and extruder, where it is pelletized. The pellets are pneumatically conveyed to blending silos for homogenization, and then sent to packing lines, where they are packed in bags before being sent to storage.
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Production Process Information
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Production Costs Datasheet
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Operating Cost Details
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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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