Production Cost Report
ICC - Is Bespoken: 0
ICC - Main References: ?
ICC - Issue: B
ICC - Volume: 219
ICC - Report ID: 219-B
ICC - Report Location: United States
ICC - Is Popular: 0
ICC - Is Developed: 1
ICC - Title: Sodium Polyacrylate Production
ICC - Show Overview: 1
ICC - Report Location ID: 1
ICC - Plant Capacity Unit ID: 14
ICC - Volume Reports List: 219-A
ICC - Related Reports List: 007-C,110-A,007-D,110-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/219-B.jpg
ICC - Process Overview Text: <h6>Product</h6> <p><b>Sodium Polyacrylate</b>. Sodium Polyacrylate is a sodium salt of polyacrylic acid. This cross-linked (network) polymer is produced on commercial scale by the free-radical polymerization of a mixture of acrylic acid and sodium acrylate, with a crosslinking agent (e.g., trimethylolpropane triacrylate). The Sodium Polyacrylate structure is actually that of polyacrylic acid, in which the carboxylic acid groups in repeating units are neutralized with sodium counter-ion. Sodium Polyacrylate is a white, granular, odorless solid at room temperatures, available commercially as a powder.</p> <h6>Raw Materials</h6> <p><b>Chemicals</b>. </p> <b>Glacial Acrylic Acid</b>. Glacial acrylic acid is a highly concentrated form of acrylic acid, valued for its role in the production of superabsorbent polymers, used in personal hygiene products such as diapers and sanitary products, as well as in paints and coatings. Glacial acrylic acid is produced through the oxidation of propylene and stored as a clear, highly corrosive liquid. Its high purity and reactivity make it an important chemical for polymerization and copolymerization processes in numerous industries.</p> <b>Caustic Soda</b>. Causic soda (NaOH), also known as sodium hydroxide, is a major inorganic used in several industries. Most of caustic soda production is used in the manufacture of chemicals, such as propylene oxide and sodium salts. Electrolysis of sodium chloride accounts for most of today’s installed capacity for caustic soda production, which also generates chlorine. </p>
ICC - Process Schematic Image: //cdn.intratec.us/images/icc/process-schematics/219-B.jpg
ICC - Process Schematic Text: <p>The process under analysis comprises three major sections: (1) Polymerization; (2) Particles size Reduction; and (3) Surface Cross-Linking and Packaging.</p><p>Polymerization. Acrylic acid is neutralized by a sodium hydroxide solution, resulting in a solution of sodium acrylate monomer. This solution is sent to another area, where it is continuously mixed with additional acrylic acid, a mix of chemicals that serves as polymerization initiator, and trimethylolpropane triacrylate, used as cross-linking agent. Such feed stream is then pumped onto a continuous, moving belt reactor, where the polymerization occurs, yielding a Sodium Polyacrylate gel.</p><p>Particles size reduction. The gel is passed through an extrusion unit, where the gel particles diameter is reduced to a range of 0.5–3 cm, in a way to increase the surface area and speed the drying step carried out in a circulating belt dryer, in which the gel water content is reduced to 5 – 10 wt.%. Residual acrylic acid and unreacted monomer also evaporate together with the water. The dried product is ground and classified. The particles are passed through an attrition mill and through roll crushers, yielding particles with grain size between 0.15 and 0.8 mm, which are then sieved with vibrating screens: overflow particles are returned to milling, while fines are partly recycled to the monomer solution, with the remainder sent to surface cross-linking.</p><p>Surface Cross-Linking and Packaging. Initially, a surface-crosslinking agent solution composed of 1,4-butanediol / propylene glycol / water / isopropanol is sprayed onto the dried polymer particles, in a vertical mixer. The coated polymer particles are then routed to a disk dryer, where they are dried thermally at 150 to 200° C for the surface cross-linking reaction occur. Afterwards, the Sodium Polyacrylate particles are packed and stored.</p><p></p>
ICC - Short Description: It presents the economics of Sodium Polyacrylate production from glacial acrylic acid and sodium hydroxide in the United States. In this process, acrylic acid is partially neutralized by sodium hydroxide, yielding a solution of sodium acrylate monomers, which is subsequently polymerized to Sodium Polyacrylate via copolymerization of acrylic acid and its salts.
ICC - Main Product: Sodium Polyacrylate
ICC - Plant Capacity: 120.00
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Sodium Polyacrylate Production

Sodium Polyacrylate Production Costs Report | Issue B | Q2 2024

Production Cost Report

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

This report presents a cost analysis of a 120 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

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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 Sodium Polyacrylate 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 Sodium Polyacrylate 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 Sodium Polyacrylate 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 Sodium Polyacrylate 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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