Emulsion Styrene Butadiene Rubber from Styrene and Butane
Styrene Butadiene Rubber Production Costs Report | Issue E | Q3 2024
Report Details |
140 kta United States-based plant | Q3 2024 | 107 pages |
This report presents a cost analysis of a 140 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 SBR production from n-butane and styrene. In this process, 1,3-Butadiene is initially produced from n-butane via a dehydrogenation process that is similar to Lummus Catadiene. Then, styrene and butadiene are polymerized via a typical cold emulsion process for generating a non-oil extended, non-staining grade of emulsion SBR (similar to 1502).
The report provides a comprehensive study of Styrene Butadiene Rubber production and related Styrene Butadiene Rubber production cost, covering three key aspects: a complete description of the Styrene Butadiene Rubber production process examined; an in-depth analysis of the related Styrene Butadiene Rubber plant capital cost (Capex); and an evaluation of the respective Styrene Butadiene Rubber plant operating costs (Opex).
The Styrene Butadiene Rubber 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 Styrene Butadiene Rubber 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 Styrene Butadiene Rubber 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 Overview

Product
SBR. Styrene Butadiene Rubber (a.k.a. SBR, SBR Latex) is a synthetic polymer made of monomers 1,3-butadiene and styrene. In the copolymer generated, the butadiene molecule may assume three different forms, according to the way it is connected to the styrene component: (1) Cis 1,4-Butadiene; (2) Trans 1,4-Butadiene; and (3) Vinyl Butadiene. It represents by far the biggest market share between synthetic elastomers produced worldwide. This elastomer offers excellent abrasion resistance, excellent water resistance, good physical properties and easy processing. These properties vary depending on the molecular weight and styrene to butadiene ratio. There's two main Styrene-Butadiene polymer types: Styrene-Butadiene Latex and Styrene-Butadiene Rubber (SBR). SBR has a higher butadiene content than Latex and this makes it more elastic-like.
Raw Materials
Butane. Butane is an essential component of the oil and gas industry, used primarily as a fuel and a feedstock for the petrochemical sector. It is a highly flammable hydrocarbon and serves in various applications such as blending with propane in liquefied petroleum gas (LPG) for domestic and industrial heating, as well as in the production of gasoline and synthetic rubber. Butane is typically extracted from natural gas or crude oil refining. It is stored as a liquid under pressure or at low temperatures, ensuring ease of transport and handling.
Styrene. Styrene is a largely available commodity generally produced from ethylbenzene by several means. One of the commercial routes for styrene production relies on the alkylation of benzene with ethylene for generating the ethylbenzene, which is then dehydrogenated to styrene in vapor phase with steam.
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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 Styrene Butadiene Rubber 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 Styrene Butadiene Rubber 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 Styrene Butadiene Rubber 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 Styrene Butadiene Rubber 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 Styrene Butadiene Rubber Production Cost Reports
High Solids Styrene Butadiene Latex Production
This report presents the economics of high solids content SBR Latex production starting from butadiene and styrene. The analysis, based on a plant located in the United States, approaches a typical cold emulsion process. For generating a high solids latex with high butadiene content, the obtained low solids latex is further concentrated after polymerization.
Details: 160 kta United States-based plant | Q3 2024 | 107 pages | Issue C From $799 USD
The cost analyses presented in this report target a 160 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.
Low Solids Styrene Butadiene Latex Production
This report targets SBR Latex production in the United States via a typical cold emulsion polymerization process. The main product generated is a low solids content SBR Latex with high styrene content.
Details: 160 kta United States-based plant | Q3 2024 | 107 pages | Issue D From $799 USD
The cost analyses presented in this report target a 160 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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