Isophthalic Unsaturated Polyester Production
Unsaturated Polyester Resin Production Costs Report | Issue A | Q4 2024
| Report Details |
| 70 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 70 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 Isophthalic Unsaturated Polyester production from maleic anhydride, isophthalic acid, propylene glycol and styrene using a two-stage batch process located in the United States. In the first stage, the glycol and isophthalic acid react to produce a cleat melt. Maleic anhydride is added subsequently and the resin is completed.
The report provides a comprehensive study of Unsaturated Polyester Resin production and related Unsaturated Polyester Resin production cost, covering three key aspects: a complete description of the Unsaturated Polyester Resin production process examined; an in-depth analysis of the related Unsaturated Polyester Resin plant capital cost (Capex); and an evaluation of the respective Unsaturated Polyester Resin plant operating costs (Opex).
The Unsaturated Polyester Resin 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 Unsaturated Polyester Resin 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 Unsaturated Polyester Resin 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 three major sections: (1) Esterification; (2) Cross-linking; and (3) Glycols recovery.
Esterification. This first step involves the polycondensation between a combination of isophthalic anhydride, maleic anhydride and propylene glycol in a process comprised of two-stages. In the first stage, isophthalic acid and propylene glycol react, producing a clear melt, while the second stage comprises the addition of maleic anhydride. The esterification reactor is equipped with stirrers and a cooling and heating internal coil. It is fed with nitrogen to generate an inert blanket. The high temperatures in the reactor cause the evaporation of the glycols and the water generated in the reaction.
Cross-linking. The cross-linking is carried out in a different vessel, where the polycondensation product is dissolved in styrene and the reaction takes place. In this reaction, the vinyl radical in styrene monomer reacts with the unsaturation in the polyester chains, thus linking different chains. Also during this step, promoters are added to initiate the copolymerization and inhibitors are added to avoid polymer premature gelation. At last, the final product is charged into drums and stored in a warehouse.
Glycols recovery. A water separation column receives the overhead vaporous glycol-water mixture from the reactor. The column top temperature is kept at 100 - 105 °C in such a way that the column overhead product contains only water, which is further routed to a condenser and discarded. The glycol-rich bottom product is recycled to the reactor.
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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 Unsaturated Polyester Resin 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 Unsaturated Polyester Resin 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 Unsaturated Polyester Resin 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 Unsaturated Polyester Resin 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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