Polyester Thermoplastic Polyurethane from MDI and Polyester Diol
Polyurethane Production Costs Report | Issue A | Q4 2024
| Report Details |
| 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.
Report Abstract
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.
The report provides a comprehensive study of Polyurethane production and related Polyurethane production cost, covering three key aspects: a complete description of the Polyurethane production process examined; an in-depth analysis of the related Polyurethane plant capital cost (Capex); and an evaluation of the respective Polyurethane plant operating costs (Opex).
The Polyurethane 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 Polyurethane 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 Polyurethane 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 two major sections: (1) Polyesterification and (2) Extrusion & Finishing.
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.
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.
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Production Process Information
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Production Costs Datasheet
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Operating Cost Details
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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 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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