Polybutadiene Production from n-Butane
Butadiene Rubber Production Costs Report | Issue B | 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
This report presents an economic analysis of an integrated unit for producing Polybutadiene starting from n-butane located in the United States. Initially, n-butane is dehydrogenated to butadiene, using a process similar to Lummus Catadiene. Then, the butadiene is polymerized to polybutadiene via a typical solution process.
The report provides a comprehensive study of Butadiene Rubber production and related Butadiene Rubber production cost, covering three key aspects: a complete description of the Butadiene Rubber production process examined; an in-depth analysis of the related Butadiene Rubber plant capital cost (Capex); and an evaluation of the respective Butadiene Rubber plant operating costs (Opex).
The Butadiene Rubber 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 Butadiene Rubber 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 Butadiene Rubber 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 4 major sections: (1) n-Butane dehydrogenation; (2) 1,3-Butadiene purification; (3) Polymerization; and (4) Rubber molding.
n-Butane dehydrogenation. Butane and butenes are heated to dehydrogenation temperature. They pass through fixed beds of chromia-alumina catalysts in the reactors and are converted into butadiene.
1,3-Butadiene purification. The reactor product is quenched for removal of polymeric compounds. The quenched gas is compressed and partially condensed. The liquid condensate, containing butadiene, is fed to a series of distillation columns, from which a butadiene-rich C4 stream is obtained. This stream is then submitted to extractive distillation in the presence of N-methylpyrrolidinone used as solvent, yielding high-purity Butadiene. Recovered butane and butenes are recycled to dehydrogenation, while other hydrocarbons are used as fuel.
Polymerization. High-purity Butadiene is pre-treated for removal of polymerization inhibitors as well as residual impurities. The treated Butadiene is dissolved in hexane and fed to a series of two continuously stirred polymerization reactors. Polymerization takes place in those reactors and is only interrupted by stopping agents when the desired molecular-weight is achieved.
Rubber molding. The polymer slurry from polymerization is passed through a flasher and subsequently through a steam stripper for hexane solvent recovery. Hexane recovered by flashing is directly recycled while hexane recovered via stripping must be further separated from water before being recycled. A crumb-water slurry is obtained and fed to a drying step. The dried crumbs are cooled with air, weighed, baled and stored.
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Production Process Information
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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 Butadiene Rubber 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 Butadiene Rubber 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 Butadiene Rubber 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 Butadiene Rubber 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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The cost analyses presented in this report target a 120 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.
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