Polycarbonate Production from BPA and Phosgene
Polycarbonate Production Costs Report | Issue A | Q4 2024
| Report Details |
| 200 kta United States-based plant | Q4 2024 | 107 pages |
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 report presents the economics of Polycarbonate (PC) production from bisphenol A (BPA) and phosgene in the United States, via a typical interfacial process. In this process, BPA, dissolved in a caustic soda solution, is reacted with phosgene, in an organic solution, at the interface of the two phases. The carbonate oligomers produced are then polycondensed to Polycarbonate.
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 three major sections: (1) Polymerization; (2) Purification; and (3) Finishing.
Polymerization. Initially, A caustic soda solution, 50 wt%, is mixed with the Bisphenol A and demineralized water, to create a solution of bisphenol-sodium salt, so Bisphenol A solubility in the aqueous phase increases. Phosgene is prone to suffer hydrolysis in an aqueous medium, so it is rather dissolved in an inert organic medium, in this process dichloromethane is used. The reaction is then conducted by mixing these two phases under severe turbulent flow. It is promoted by the addition of a phase transfer catalyst and alkaline medium. A chain stopper agent is added to control the polymer molecular weight. This reaction is conducted in two steps, first the reaction between the bisphenol-sodium salt and phosgene is favored, producing a variety of oligomers, primary chlorocarbonic esters. In the second step these oligomers are condensed into high molecular weight polycarbonate.
Purification. The final output from the polymerization reaction is then fed to a decanter, from which a dichloromethane phase rich in polycarbonate is recovered. This organic stream is then subjected to a series of washes to remove unconverted raw materials and other contaminants. Then, a series of drying operations are conducted to recover a dry polycarbonate solid. Aqueous stream from caustic wash are mixed with an an organic stream from drying operations and are fed to a distillation column, where a top product containing dichloromethane is obtained and recycled to oligomerization.
Finishing. The flakes are mixed with additives and fed to twin-screw extruder, where they are homogenized and pelletized. The pellets are homogenized, packed and stored.
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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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