Phenol-Formaldehyde Resins Production
Phenol-Formaldehyde Resins Production Costs Report | Issue A | Q4 2024
| Report Details |
| 75 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 75 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 a conventional batch polymerization for Phenol-Formaldehyde Resins production, starting from phenol and formalin. The economic analysis approaches a plant located on the United States.
The report provides a comprehensive study of Phenol-Formaldehyde Resins production and related Phenol-Formaldehyde Resins production cost, covering three key aspects: a complete description of the Phenol-Formaldehyde Resins production process examined; an in-depth analysis of the related Phenol-Formaldehyde Resins plant capital cost (Capex); and an evaluation of the respective Phenol-Formaldehyde Resins plant operating costs (Opex).
The Phenol-Formaldehyde Resins 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 Phenol-Formaldehyde Resins 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 Phenol-Formaldehyde Resins 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
Phenol-Formaldehyde Resins. Phenol-Formaldehyde Resins (a.k.a. PF, Phenolic resins) are synthetic polymers of phenol and formaldehyde. They were the first commercialized synthetic plastics and are still very important industrial polymers. The most common application of Phenol-Formaldehyde Resins is in adhesives for bonding wood products, especially those desired for exterior plywood. It has great moisture resistance, low cost and good thermal and flame resistance.
Raw Materials
Formalin. Formaldehyde is a colorless, strong-smelling gas remarkably versatile as a chemical intermediate - it is widely used for the production of resins and coatings employed in the manufacture of building materials and household products. Since the pure gas slowly polymerizes at temperatures lower than 80°C, formaldehyde is usually available as a liquid solution in water with small amounts of methanol. This solution is called formalin. Most of world's formalin is commercially manufactured from methanol and air in the presence of a silver (or a metal oxide) catalyst.
Phenol. Phenol is an aromatic compound primarily used in the production of phenolic resins and bisphenol-A (BPA), which is a precursor for polycarbonate plastics and epoxy resins. It is also used in herbicides, pharmaceuticals, and adhesives. Phenol is produced from cumene via the cumene hydroperoxide process and is stored as a crystalline solid or liquid. Its high reactivity with formaldehyde in resin formation makes it critical in producing durable materials for construction and electronics.
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Production Process Information
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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 Phenol-Formaldehyde Resins 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 Phenol-Formaldehyde Resins 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 Phenol-Formaldehyde Resins 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 Phenol-Formaldehyde Resins 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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