Production Cost Report
ICC - Is Bespoken: 0
ICC - Main References: ?
ICC - Issue: C
ICC - Volume: 288
ICC - Report ID: 288-C
ICC - Report Location: United States
ICC - Is Popular: 0
ICC - Is Developed: 1
ICC - Title: Polyether Polyurethane from TDI and Polyether Triol (Typical Foaming)
ICC - Show Overview: 1
ICC - Report Location ID: 1
ICC - Plant Capacity Unit ID: 14
ICC - Volume Reports List: 288-A,288-B,288-D,288-E
ICC - Related Reports List: 059-D,059-F
ICC - Report Location Code: USA
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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-C.jpg
ICC - Process Overview Text: <h6>Product</h6> <p><b>Polyether Polyurethane</b>. Polyether Polyurethane is a polyurethane variant known for its superior flexibility, hydrolytic stability, and resilience, commonly used in soft foams, elastomers, and sealants. It is made from polyether polyols. It offers excellent moisture resistance, making it ideal for wet environments.</p> <h6>Raw Materials</h6> <p><b>Chemicals</b>. </p> <b>TDI</b>. TDI (Toluene Diisocyanate) is a critical raw material for producing flexible polyurethane foams, which are used in furniture, mattresses, and automotive seating. It is also used in coatings and adhesives. TDI is produced through the nitration of toluene followed by phosgenation. It is stored as a liquid and is highly reactive, requiring careful handling due to its toxicity and sensitivity to moisture.</p> <b>Polyether Triol</b>. Polyether Triol is used in producing polyurethane foams, elastomers, and sealants by reacting with isocyanates. It contributes to polymers with flexible or rigid properties depending on its molecular weight. Synthesized through the polymerization of propylene oxide or ethylene oxide, it is stored as a viscous liquid. Its customization potential allows manufacturers to tailor material characteristics for specific industrial needs.</p>
ICC - Process Schematic Image: //cdn.intratec.us/images/icc/process-schematics/288-C.jpg
ICC - Process Schematic Text: <p>The process under analysis comprises two major sections: (1) Foaming and (2) Finishing.</p><p>Foaming. A polyether triol solution, toluene diisocyanate (TDI), and water, as well as other chemicals (e.g., catalyst, CO2, and additives), are fed into the first section of a foaming equipment – the mixing chamber. They are thoroughly mixed and directed to an inclined conveyor belt, through an injector. There, the reaction effectively takes place: TDI reacts with the polyether triol, producing a rectangular Polyurethane slab. Finally, in the last part of Foaming equipment, it is air-cooled and directed to Finishing steps.</p><p>Finishing. After Foaming, Flexible Slabstock Polyurethane is sent to curing, for about 12 hours. The slabs are placed in curing storage facilities, where they finish cooling down and reach the expected properties. Then, Polyurethane is directed to Finishing steps, in which it is cut and packed.</p>
ICC - Short Description: This report examines the costs related to Flexible Slabstock Polyether Polyurethane production from toluene diisocyanate (TDI) and a polyether triol in the United States, via a typical foaming process.
ICC - Main Product: Polyurethane
ICC - Plant Capacity: 13.00
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Polyether Polyurethane from TDI and Polyether Triol (Typical Foaming)

Polyurethane Production Costs Report | Issue C | Q2 2024

Production Cost Report

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13 kta United States-based plant   |   Q2 2024   |   107 pages   |   Delivered in PDF

This report presents a cost analysis of a 13 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

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Plant Capital Cost Summary

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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

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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   |   Q2 2024   |   107 pages   |   Issue A   From $799 USD

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Polyether Thermoplastic Polyurethane from MDI and PTMEG

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Details: 20 kta United States-based plant   |   Q2 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 (VPF Process)

It presents the economics of Flexible Slabstock Polyether Polyurethane production from toluene diisocyanate (TDI) and a polyether triol in the United States. The process examined in this report is a typical variable pressure foaming (VPF) process.

Details: 3 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue D   From $799 USD

The cost analyses presented in this report target a 3 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.

Rigid Boardstock Polyester Polyurethane Production

This report analyses the economics of Rigid Boardstock Polyester Polyurethane production from polymeric isocyanate (PMPPI) and a polyester polyol in the United States. These raw materials enable the formation of a highly cross-linked molecular structure.

Details: 3 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue E   From $799 USD

The cost analyses presented in this report target a 3 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

Toluene Diisocyanate from Toluene (Liquid-Phase Phosgenation)

This report presents the economics of a typical liquid-phase phosgenation process for Toluene Diisocyanate (TDI) production from toluene and chlorine in the USA. Initially, toluene is submitted to a dinitration to produce dinitrotoluene (DNT), which is then hydrogenated to toluenediamine (TDA). This TDA is reacted with phosgene in liquid phase to yield TDI product. The phosgene used is generated from chlorine in an on-site unit.

Details: 220 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue D   From $1,499 USD

The cost analyses presented in this report target a 220 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.

Toluene Diisocyanate from Toluene (Gas-Phase Phosgenation)

This report presents the economics of TDI production from toluene and chlorine via a process similar to the Bayer Gas-Phase Phosgenation (GPP) technology in the United States. Initially, toluene is dinitrated to dinitrotoluene (DNT). Then, DNT is hydrogenated to toluenediamine (TDA). Finally, TDA reacts with phosgene in gas phase to produce TDI. The phosgene used is generated from chlorine in an on-site unit.

Details: 300 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue F   From $1,499 USD

The cost analyses presented in this report target a 300 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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