High Impact Polystyrene Production
Polystyrene Production Costs Report | Issue B | Q3 2024
Report Details |
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.
Report Abstract
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.
The report provides a comprehensive study of Polystyrene production and related Polystyrene production cost, covering three key aspects: a complete description of the Polystyrene production process examined; an in-depth analysis of the related Polystyrene plant capital cost (Capex); and an evaluation of the respective Polystyrene plant operating costs (Opex).
The Polystyrene 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 Polystyrene 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 Polystyrene 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) Pre-polymerization; (2) Polymerization; and (3) Finishing.
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.
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.
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.
Up-to-date PDF Report
Professional report based on Q3 2024 economic data, ensuring timely evaluations.
Multiple Use Cases
Ideal for investment screening, feasibility studies, cost estimates, and research planning.
Proven Methodology
Developed using a consistent methodology honed over a decade, ensuring reliable cost analyses.
Compact
$799 USD
Production Process Information
Process Consumptions
Labor Requirements
Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
Pages | Tables | Images
Read-only Online PDF Format
Updated with Q3 2024 Data
DETAILED
$1,599 USD
Production Process Information
Process Consumptions
Labor Requirements
Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
Plant Capital Cost Details
Operating Cost Details
Pages | Tables | Images
Downloadable PDF Format
Updated with Q3 2024 Data
PREMIUM
MOST POPULAR
$2,699 USD
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
Pages | Tables | Images
Print-enabled PDF Format Add-on
Updated with Q3 2024 Data
Share with Co-workers
Technical Support via Email
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.
Could Not Find the Report You Need?
Obtain a Bespoke Report
Get a report targeting the process in which you are interested
See Offer Details
Understand Bespoke Reports and how you can easily order them
Check Editions & Pricing
Complete a brief form and see a quotation for your Bespoke Report
Other Related Production Cost Reports
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
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.
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.
Details: 750 kta United States-based plant | Q3 2024 | 107 pages | Issue C From $1,199 USD
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.
+800 Reports Developed, Targeting +250 Commodities
Best-in-Class Reports
Analysis of capital and operating costs of commodity production processes. Prices starting at $799 USD
Vast Report Library
858 independent and up-to-date reports examining embryonic and established production processes
Free Sample Reports
Quickly understand the structure and depth of content of our professional reports