Production Cost Report
ICC - Is Bespoken: 0
ICC - Main References: ?
ICC - Issue: G
ICC - Volume: 200
ICC - Report ID: 200-G
ICC - Report Location: United States
ICC - Is Popular: 0
ICC - Is Developed: 0
ICC - Title: Polycarbonate Production from BPA, Phenol and Methanol
ICC - Show Overview: 1
ICC - Report Location ID: 1
ICC - Plant Capacity Unit ID: 14
ICC - Volume Reports List: 200-A,200-B,200-H,200-C,200-D,200-E,200-F
ICC - Related Reports List: 048-A,001-D,045-D,048-B,001-F
ICC - Report Location Code: USA
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ICC - Prices: {"versions":{"1":{"1":"1199","2":"1199","3":"1199"},"2":{"1":"1999","2":"1999","3":"1999"},"3":{"1":"3399","2":"3399","3":"3399"}},"currency":"USD"}
ICC - Plant Capacity Unit Name: kilo metric ton per annum
ICC - Plant Capacity Unit Short Name: kta
ICC - Process Overview Image: //cdn.intratec.us/images/icc/process-overview/200-G.jpg
ICC - Process Overview Text: <h6>Product</h6> <p><b>Polycarbonate</b>. 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.</p> <h6>Raw Materials</h6> <p><b>BPA</b>. 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.</p> <b>Methanol</b>. Methanol is a simple alcohol used as a solvent, antifreeze, and a feedstock for producing formaldehyde, acetic acid, and methyl tert-butyl ether (MTBE). It is also an alternative fuel in various energy applications. Methanol is produced from synthesis gas and is stored as a liquid. In addition to its widespread use in chemicals and fuels, methanol is increasingly used in the production of biodiesel and fuel cells, highlighting its role in renewable energy technologies.</p> <b>Phenol</b>. 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.</p>
ICC - Process Schematic Image: //cdn.intratec.us/images/icc/process-schematics/200-G.jpg
ICC - Short Description: 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.
ICC - Main Product: Polycarbonate
ICC - Plant Capacity: 150.00
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Polycarbonate Production from BPA, Phenol and Methanol

Polycarbonate Production Costs Report | Issue G | Q3 2024

Production Cost Report

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150 kta United States-based plant   |   Q3 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.

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Production Process Information

Process Consumptions

Labor Requirements

Plant Capital Cost Summary

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Production Costs Datasheet

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Production Process Information

Process Consumptions

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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

Plant Cost Breakdowns

Plant Capacity Assessment

Process Flow Diagrams

Costs in Different Countries Add-on

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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

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   |   Q3 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   |   Q3 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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Other Related Production Cost Reports

Methanol Production from Naphtha

This report presents an economic analysis of Methanol production from naphtha in the United States. In this process, naphtha undergoes partial oxidation producing syngas, which is then converted to Methanol.

Details: 1,700 kta United States-based plant   |   Q3 2024   |   107 pages   |   Issue D   From $1,199 USD

The cost analyses presented in this report target a 1,700 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.

Methanol Production from Refuse-Derived Fuels

This report provides the economics of Methanol from refuse-derived fuels (RdF) for a waste-to-methanol (WtM) process in the United States. In this process, RdF is first gasified to syngas, which is then converted to Methanol.

Details: 350 kta United States-based plant   |   Q3 2024   |   107 pages   |   Issue F   From $1,199 USD

The cost analyses presented in this report target a 350 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.

Phenol Production from Toluene

This study reviews the economics of a process producing Phenol from toluene. Initially, toluene is oxidized to benzoic acid intermediate in liquid phase, which is then converted to Phenol in the liquid phase in the presence of cupric and magnesium benzoates. The economic analysis presented assumes a plant constructed in the United States.

Details: 50 kta United States-based plant   |   Q3 2024   |   107 pages   |   Issue D   From $1,199 USD

The cost analyses presented in this report target a 50 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 (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   |   Q3 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.

Details: 200 kta United States-based plant   |   Q3 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.

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