Production Cost Report
ICC - Is Bespoken: 0
ICC - Main References: ?
ICC - Issue: B
ICC - Volume: 233
ICC - Report ID: 233-B
ICC - Report Location: United States
ICC - Is Popular: 0
ICC - Is Developed: 1
ICC - Title: High Impact Polystyrene Production
ICC - Show Overview: 1
ICC - Report Location ID: 1
ICC - Plant Capacity Unit ID: 14
ICC - Volume Reports List: 233-A,233-C,233-D,233-E
ICC - Related Reports List: 034-B,205-A,205-B,034-C,041-B,041-A
ICC - Report Location Code: USA
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ICC - Prices: {"versions":{"1":{"1":"799","2":"799","3":"799"},"2":{"1":"1599","2":"1599","3":"1599"},"3":{"1":"2699","2":"2699","3":"2699"}},"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/233-B.jpg
ICC - Process Overview Text: <h6>Product</h6> <b>HIPS</b></p></b></p> <h6>Raw Materials</h6> <p><b>Chemicals</b></p>, <p><b>Styrene</b></p>, <p><b>Butadiene Rubber</b></p>, <p><b>Ethylbenzene</b></p>, <p><b>Mineral Oil</b></p>
ICC - Process Schematic Image: //cdn.intratec.us/images/icc/process-schematics/233-B.jpg
ICC - Process Schematic Text: <p>The process under analysis comprises three major sections: (1) Pre-polymerization; (2) Polymerization; and (3) Finishing.</p><p>Pre-polymerization. Polybutadiene rubber, in bale form, is ground in a mill and fed to a high-shear in-line mixer, along with fresh styrene. The styrene is preheated so as to enhance dissolving. Liquid paraffin (mineral oil) is also added, as an internal lubricant. The solution is fed to a continuous stirred-tank reactor (CSTR) in the presence of ethylbenzene solvent, which supports control of the polymerization rate and lowers the viscosity of the polymer melt. The reaction is initiated by peroxides fed to the reactors. Zinc stearate (external lubricant) and other additives are also added to the polymer being produced. While the styrene polymerization is exothermic, reaction heat is removed by reflux cooling. In fact, the reaction media temperature has a great impact on the molecular mass of the Polystyrene being formed. This pre-polymerization is carried out to a 15 - 30 % conversion of the styrene. In the pre-polymerization, polymer morphology and particle size are largely adjusted.</p><p>Polymerization. The output from the pre-polymerization is then routed to the second polymerization step. At this point, the previously formed oligomers are fed to two plug-flow reactors where the polymerization reaction is continued. The thermal profile of the reaction media is controlled by the circulation of thermal oil inside internal coils.</p><p>Finishing. The resulting polymer slurry, with a solid content of between 60 and 90 %, is submitted to a devolatilization step where monomers are recovered, purified in a distillation column and recycled. The PS melt passes through an extrusion and pelletizing system, is packed and stored.</p>
ICC - Short Description: This study presents the economics of High Impact Polystyrene (HIPS) production from styrene in the United States, via a typical continuous bulk polymerization process, which occurs in the presence of polybutadiene. The process is split into a pre-polymerization and a polymerization step. The first step is conducted in CSTRs and the second in plug-flow reactors.
ICC - Main Product: Polystyrene
ICC - Plant Capacity: 180.00
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ICC - Table Count: {"versions":{"1":"22","2":"28","3":"34"}}

High Impact Polystyrene Production

Polystyrene Production Costs Report | Issue B | Q3 2024

Production Cost Report

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180 kta United States-based plant   |   Q3 2024   |   107 pages

This report presents a cost analysis of a 180 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

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Production Process Information

Process Consumptions

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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 Polystyrene 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 Polystyrene 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 Polystyrene 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 Polystyrene 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 Polystyrene Production Cost Reports

General Purpose Polystyrene Production

This report presents the economics of General Purpose Polystyrene (GPPS) production from styrene in the United States, via a typical continuous bulk polymerization process, split into a pre-polymerization and a polymerization step. Both steps are conducted in continuous stirred-tank reactors.

Details: 180 kta United States-based plant   |   Q3 2024   |   107 pages   |   Issue A   From $799 USD

The cost analyses presented in this report target a 180 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.

Expandable Polystyrene Production

This study presents the economics of Expandable Polystyrene (EPS) production from styrene in the United States, via a typical batch suspension polymerization process. The tiny spheres of EPS are impregnated with a physical blowing agent.

Details: 150 kta United States-based plant   |   Q3 2024   |   107 pages   |   Issue C   From $799 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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Styrene Production from Propylene & Ethylbenzene

This study presents the economics of Styrene production from chemical grade (CG) propylene and ethylbenzene in the United States. The process examined is a Propylene Oxide/Styrene Monomer (POSM) technology similar to the one owned by LyondellBasell. This process involves ethylbenzene oxidation, epoxidation, hydrogenation and dehydration steps.

Details: 850 kta United States-based plant   |   Q3 2024   |   107 pages   |   Issue B   From $1,199 USD

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Styrene Production from Ethane & Benzene (H2 as Co-Product)

This report presents the economics of Styrene production from ethane and benzene in the United States, with pure hydrogen as by-product. In this report, ethylbenzene (EB) is first generated from benzene and recycled ethylene. Then, fresh ethane and the EB are dehydrogenated to form ethylene and Styrene. The process analyzed is based on concepts proposed in patents issued to Dow and Snamprogetti.

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The cost analyses presented in this report target a 750 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.

Ethylbenzene from Benzene and Ethylene (Zeolite Catalyst)

This report presents the economics of a liquid-phase alkylation process similar to Polimeri Europa using zeolite catalyst for Ethylbenzene production from benzene and polymer grade ethylene in the United States.

Details: 850 kta United States-based plant   |   Q3 2024   |   107 pages   |   Issue A   From $799 USD

The cost analyses presented in this report target a 850 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.

Ethylbenzene from Benzene and Ethylene (CD Process)

This study provides a techno-economic analysis of a catalytic distillation (CD) process similar to CDTECH for Ethylbenzene production from benzene and dilute ethylene in the United States. This process combines the catalytic alkylation and distillation in a single operation.

Details: 600 kta United States-based plant   |   Q3 2024   |   107 pages   |   Issue B   From $799 USD

The cost analyses presented in this report target a 600 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.

Polybutadiene Production from Butadiene

This report presents the economics of Polybutadiene production from butadiene in the United States, via a typical solution process. In this process, butadiene is polymerized in the presence of a Ziegler-Natta catalyst and a solvent to produce Polybutadiene.

Details: 120 kta United States-based plant   |   Q3 2024   |   107 pages   |   Issue A   From $799 USD

The cost analyses presented in this report target a 120 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.

Polybutadiene Production from n-Butane

This report presents an economic analysis of an integrated unit for producing Polybutadiene starting from n-butane located in the United States. Initially, n-butane is dehydrogenated to butadiene, using a process similar to Lummus Catadiene. Then, the butadiene is polymerized to polybutadiene via a typical solution process.

Details: 120 kta United States-based plant   |   Q3 2024   |   107 pages   |   Issue B   From $1,199 USD

The cost analyses presented in this report target a 120 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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