Polycarbonate Production from BPA and DPC
Polycarbonate Production Costs Report | Issue B | Q2 2024
Report Details |
200 kta United States-based plant | Q2 2024 | 107 pages | Delivered in PDF |
This report presents a cost analysis of a 200 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 study presents the economics of Polycarbonate (PC) production from bisphenol A (BPA) and diphenyl carbonate (DPC) in the United States, via a typical melt process. In this process, DPC is transesterified with BPA to form PC and phenol as by-product. The reaction is conducted in oligomerization and polymerization.
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 Schematic
The process under analysis comprises 3 major sections: (1) Polymerization; (2) Phenol Purification; and (3) Polycarbonate Pelletizing.
Polymerization. Diphenyl carbonate melt, bisphenol A and sodium dihydrogen phosphite are mixed and heated to form a melt. The stream is fed to a oligomerization step, where low molecular weight oligomers are generated. The oligomers are directed to more severe conditions, then polymerization is completed in two CSTR operating in series. Polymerization is interrupted by addition of n-butyl tosylate, which deactivates the catalyst. Phenol and other by-products are continuously removed from the process.
Phenol Purification. The by-products are sent to a distillation column. Phenol is withdrawn from overhead and exported to nearby facility.
Pelletizing. The polymer melt is filtered, and a mix of additives is added. The mixture is homogenized and pelletized. Finally, the pellets are conveyed to homogenization system and fed to the packing system.
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Production Process Information
Process Consumptions
Labor Requirements
Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
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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
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Updated with Q2 2024 Data
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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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Updated with Q2 2024 Data
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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: 150 kta United States-based plant | Q2 2024 | 107 pages | Issue F From $1,499 USD
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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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