Isosorbide Polycarbonate Production
Polycarbonate Production Costs Report | Issue C | Q2 2024
Report Details |
150 kta United States-based plant | Q2 2024 | 107 pages | Delivered in PDF |
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 examines the costs related to Isosorbide Polycarbonate production from glucose and ethylene oxide in the USA, using a melt polymerization process similar of isosorbide and diphenyl carbonate (DPC) to the one proposed by Mitsubishi Chemical. Isosorbide is produced from glucose and DPC from ethylene oxide. Ethylene glycol is generated as a by-product.
The report provides a comprehensive study of Polycarbonate production and related Polycarbonate production cost, covering three key aspects: a complete description of the Polycarbonate production process examined; an in-depth analysis of the related Polycarbonate plant capital cost (Capex); and an evaluation of the respective Polycarbonate plant operating costs (Opex).
The Polycarbonate 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 Polycarbonate 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 Polycarbonate 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
Products
Isosorbide Polycarbonate. Polycarbonate (a.k.a. PC) is a thermoplastic polymer/resin, derived from diphenyl carbonate, phosgene and bisphenol A. The polymer is easily molded and thermoformed, and for that, along with its properties, polycarbonates are among the most used plastics in industry. Polycarbonate has a high impact and dielectric strength, heat resistance, it is noncorrosive and extremely dimensionally stable. Depending on the grade, the resulting material is translucent, so PC has been used as a substitute to glass, although it is not its primary use, due to PC being more expensive than polymethyl methacrylate (acrylic). The main uses of PC are in the construction industry and as engineering materials. Because of their unusual properties (e.g. toughness, clarity), Polycarbonates figure among the top engineering thermoplastics.
Ethylene Glycol. Ethylene glycol, also known as monoethylene glycol or MEG, is the simplest diol, with chemical formula C2H6O2. Like other glycols, ethylene glycol undergoes reactions common to monohydric alcohols forming esters, acetals, ethers, and similar products. Most of monoethylene glycol has been produced from ethylene via ethylene oxide intermediate, generating di- and tri-ethylene glycol as well. Commercially, ethylene glycol is available in three grades: fiber grade, with min. 99.8% of purity; industrial grade with min. 99.5% of purity and antifreeze grade with min. 98% of purity.
Raw Materials
Glucose Syrup. Glucose (C6H12O6), also known as D-glucose and dextrose, is the most abundant sugar in nature. Commercial glucose products are available in both dry and syrup forms in a variety of purities and concentrations. Glucose uses include pharmaceuticals, food, chemicals and fuels. This compound is used as raw material in fermentative processes for the production of vitamins, organic acids, antibiotics, amino acids, enzymes, and polysaccharides.
Ethylene Oxide. Ethylene Oxide (also known as Oxirane and Epoxyethane) is the simplest cyclic ether. Very reactive, Ethylene Oxide is one of the most versatile chemical intermediates, converted in a range of products, and also used as disinfectant, sterilizing agent, and fumigant. Currently, Ethylene Oxide is produced primarily by direct oxidation processes, based on the catalytic oxidation of ethylene with oxygen over a silver-based catalyst.
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Production Process Information
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Production Costs Datasheet
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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 Polycarbonate 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 Polycarbonate 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 Polycarbonate 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 Polycarbonate 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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Details: 200 kta United States-based plant | Q2 2024 | 107 pages | Issue B From $799 USD
The cost analyses presented in this report target a 200 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.
Polycarbonate Production from BPA and Ethylene Oxide
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Details: 150 kta United States-based plant | Q2 2024 | 107 pages | Issue D From $1,199 USD
The cost analyses presented in this report target a 150 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.
Polycarbonate Production from Phenol & Acetone
This report analyses the economics of Polycarbonate (PC) production from phenol, acetone and phosgene in the United States. Initially, BPA is manufactured by condensation of phenol with acetone. Then, BPA is reacted with phosgene at the interface of a two-phase mixture. The carbonate oligomers produced are then polycondensed to Polycarbonate resin.
Details: 250 kta United States-based plant | Q2 2024 | 107 pages | Issue E From $1,199 USD
The cost analyses presented in this report target a 250 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.
Polycarbonate Production from Phenol, Acetone and Methanol
This report presents the economics of Polycarbonate (PC) production from phenol, acetone, and methanol in the United States. BPA is manufactured by condensation of phenol with acetone. To form diphenyl carbonate (DPC), methanol is carbonylated producing dialkyl carbonate which is reacted with phenol. The DPC and BPA are transesterified and polycondensed to generate PC.
Details: 150 kta United States-based plant | Q2 2024 | 107 pages | Issue F From $1,499 USD
The cost analyses presented in this report target a 150 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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Details: 150 kta United States-based plant | Q2 2024 | 107 pages | Issue G From $1,199 USD
The cost analyses presented in this report target a 150 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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Details: 150 kta United States-based plant | Q2 2024 | 107 pages | Issue H From $1,199 USD
The cost analyses presented in this report target a 150 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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