Production Cost Report
ICC - Is Bespoken: 0
ICC - Main References: ?
ICC - Issue: A
ICC - Volume: 288
ICC - Report ID: 288-A
ICC - Report Location: United States
ICC - Is Popular: 0
ICC - Is Developed: 1
ICC - Title: Polyester Thermoplastic Polyurethane from MDI and Polyester Diol
ICC - Show Overview: 1
ICC - Report Location ID: 1
ICC - Plant Capacity Unit ID: 14
ICC - Volume Reports List: 288-C,288-B,288-D,288-E
ICC - Related Reports List: 065-A,027-A,019-A,027-B,019-B
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/288-A.jpg
ICC - Process Overview Text: <h6>Product</h6> <b>Polyester Thermoplastic Polyurethane </b></p></b></p> <h6>Raw Materials</h6> <p><b>Chemicals</b></p>, <p><b>Butanediol</b></p>, <p><b>Fiber Grade Adipic Acid</b></p>, <p><b>MDI</b></p>
ICC - Process Schematic Image: //cdn.intratec.us/images/icc/process-schematics/288-A.jpg
ICC - Process Schematic Text: <p>The process under analysis comprises two major sections: (1) Polyesterification and (2) Extrusion & Finishing.</p><p>Polyesterification. Adipic acid and butanediol (BDO) are mixed, together with the catalyst, and fed into the Esterification batch-reactor. The product of Esterification (monomer), BDO, and the catalyst are fed into the Polycondensation Reactor. In this second batch-reactor, monomers and oligomers are condensed in order to form low-molecular weight polybutanediol adipate, releasing BDO, recovered in a distillation column (Butanediol Recovery Column). The light unreacted reagents and side products of esterification and polycondensation – mainly water – are sent to the Butanediol Recovery Column, where they are removed from crude BDO and discarded. BDO is recovered at the bottom and recycled to Esterification. Before being fed into the extruder, polybutanediol adipate is mixed with butanediol in a buffer mixing tank.</p><p>Extrusion & Finishing. Methylene diphenyl diisocyanate (MDI) and the polymeric solution from Polyesterification section, as well as other chemicals (e.g., catalyst and additives) are fed into the first section of a three-section extruder (feeding section). Then, in the second section, mixing, they are thoroughly mixed and directed to the last section, extrusion, where the reaction effectively takes place: MDI reacts with the polyester diol, producing Thermoplastic Polyurethane Elastomer. After Extrusion, TPU is sent to Finishing steps, in which it is pelletized, homogenized, and packed. </p>
ICC - Short Description: This report presents the economics of Polyester Thermoplastic Polyurethane (TPU) production from methylene diphenyl diisocyanate (MDI) and poly(1,4-butanediol adipate) in the United States, via a typical one-shot polymerization in a twin-screw reactive extruder.
ICC - Main Product: Polyurethane
ICC - Plant Capacity: 20.00
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Polyester Thermoplastic Polyurethane from MDI and Polyester Diol

Polyurethane Production Costs Report | Issue A | Q4 2024

Production Cost Report

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20 kta United States-based plant   |   Q4 2024   |   107 pages

This report presents a cost analysis of a 20 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

Operating Cost Summary

Production Costs Datasheet

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Production Process Information

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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 Polyurethane 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 Polyurethane 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 Polyurethane 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 Polyurethane 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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Details: 20 kta United States-based plant   |   Q4 2024   |   107 pages   |   Issue B   From $799 USD

The cost analyses presented in this report target a 20 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.

Polyether Polyurethane from TDI and Polyether Triol (Typical Foaming)

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Details: 13 kta United States-based plant   |   Q4 2024   |   107 pages   |   Issue C   From $799 USD

The cost analyses presented in this report target a 13 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

Adipic Acid Production from Cyclohexane

This report presents a cost analysis of Adipic Acid production from cyclohexane in the United States. The process examined is a two-stage oxidation process, in which cyclohexane is initially oxidized with air to produce KA oil (mixture of cyclohexanone and cyclohexanol), and further oxidized with nitric acid to produce Adipic Acid.

Details: 350 kta United States-based plant   |   Q4 2024   |   107 pages   |   Issue A   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.

Bio-Adipic Acid Production from Glucose (Chemical Catalytic Process)

This report shows a feasibility study of Bio-Adipic Acid production from glucose syrup in a plant located in the United States. The route examined is a two-step catalytic process similar to Rennovia process. In this process, glucose is first oxidized to produce glucaric acid, which is then hydrogenated to produce Adipic Acid.

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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.

Bio-Butanediol Production from Glucose (Direct Fermentation)

This report presents the economics of bio-based 1,4-Butanediol (BDO) production from glucose syrup in a plant located in the United States. This process, similar to the one proposed by Genomatica, consists in a direct fermentation of glucose syrup, producing BDO, which is then submitted to purifying steps.

Details: 75 kta United States-based plant   |   Q4 2024   |   107 pages   |   Issue A   From $799 USD

The cost analyses presented in this report target a 75 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.

Bio-Butanediol from Glucose (Succinic Acid as Intermediate)

This report examines the costs related to Butanediol production from glucose syrup. Initially, glucose is fermented to produce succinic acid, which is then hydrogenated to produce butanediol. The economic analysis is based on a plant constructed in the United States.

Details: 50 kta United States-based plant   |   Q4 2024   |   107 pages   |   Issue B   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.

MDI Production from Aniline (Phosgenation Process)

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