Polycarbonate Production from BPA and Ethylene Oxide
Polycarbonate Production Costs Report | Issue D | Q4 2024
| Report Details |
| 150 kta United States-based plant | Q4 2024 | 107 pages |
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
It presents the economics of Polycarbonate (PC) production from bisphenol A (BPA) and ethylene oxide in the United States, via a typical melt polymerization of BPA with diphenyl carbonate (DPC) via transesterification. The BPC is generated by oxidative carbonylation of phenol with 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
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
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.
BPA. Bisphenol A is a high volume production organic compound, synthesized from phenol and acetone. It has been produced in commercial since the 1950's and is mostly used in the production of polycarbonate plastic and epoxy resins. Nowadays its use in products with contact with food has been decreasing, mostly in the United States, due to a rising concern on the negative health effects it might cause.
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Production Process Information
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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 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
Other Polycarbonate Production Cost Reports
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 | Q4 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.
Polycarbonate Production from BPA, Phenol and Methanol
It presents the economics of Polycarbonate (PC) production from bisphenol A (BPA), phenol and methanol in the United States. Initially, methanol is carbonylated with carbon monoxide, producing dialkyl carbonate which are reacted with phenol to form diphenyl carbonate. It is then transesterified with BPA and polycondensed to generate PC.
Details: 150 kta United States-based plant | Q4 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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Other Related Production Cost Reports
BPA from Acetone and Phenol (Hydrogen Chloride Catalyst)
This report presents the economics of Bisphenol A (BPA) production in the United States via a condensation reaction of acetone with phenol catalyzed by hydrogen chloride.
Details: 30 kta United States-based plant | Q4 2024 | 107 pages | Issue A From $799 USD
The cost analyses presented in this report target a 30 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.
BPA from Acetone and Phenol (Ion-Exchange Resin Catalyst)
This report presents a techno-economic analysis of Bisphenol A (BPA) production in the United States, via a process similar to Dow's QBIS technology. In this process, BPA is produced by the reaction of acetone with phenol catalyzed by a cation-exchange resin.
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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.
Ethylene Oxide Production from Ethylene (Pure Oxygen as Oxidizer)
This report approaches the economics of Ethylene Oxide production from ethylene in the United States using a typical direct oxidation process. In the process examined, pure oxygen is used as the oxidizing agent. The reaction is carried out in the gaseous phase.
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The cost analyses presented in this report target a 550 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: 550 kta United States-based plant | Q4 2024 | 107 pages | Issue B From $999 USD
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