Commodity Production Costs Report
BPA from Acetone and Phenol (Hydrogen Chloride Catalyst)
Bisphenol A Operating Costs & Plant Construction Costs
This report presents the economics of Bisphenol A (BPA) production in the United States via a condensation reaction of acetone with phenol catalyzed by hydrogen chloride.
The report provides a comprehensive study of Bisphenol A production and related Bisphenol A production cost, covering three key aspects: a complete description of the Bisphenol A production process examined; an in-depth analysis of the related Bisphenol A plant capital cost (Capex); and an evaluation of the respective Bisphenol A plant operating costs (Opex).
The Bisphenol A 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 Bisphenol A 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 Bisphenol A plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Key reference(s): ?
The process under analysis comprises three major sections: (1) Condensation reaction; (2) Purification and (3) Finishing.
Condensation reaction. Phenol and acetone along with hydrogen chloride are fed to two agitated jacketed reactors in series. In the reactors, the condensation reaction between phenol and acetone occurs, producing a crude product with Bisphenol A isomers. The crude product is subsequently passed through two distillation columns for recovering hydrogen chloride and unreacted phenol to be recycled to the process. Distilled hydrochloric acid is fed to a recovery area for removal of water before recycling back to the reactor.
Purification. The bottom stream from the phenol column is fed to a distillation column for the removal of a portion of the o,p-BPA isomer, some impurities, and residual phenol. The column's overhead stream containing the removed compounds is returned to the reactor while the bottom stream is sent to a thin-film evaporator, in which Bisphenol A is separated from high boiling by-products and tars. The Bisphenol A stream is then mixed with benzene and fed to a crystallizer, where the temperature is reduced and the desired p,p-BPA isomer is precipitated. The resulting slurry passes through a centrifuge and the Bisphenol A crystals are dryed.
Finishing. The dried Bisphenol A cystals are melted, prilled and then classified; the oversize solids are returned for further processing, while the Bisphenol A product is directed to packing. Polycarbonate grade Bisphenol A prills with a purity of 99.5 wt% is obtained as the final product.
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Professional report based on Q3 2024 economic data, ensuring timely evaluations.
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Bisphenol A 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 Bisphenol A 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 Bisphenol A 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 Bisphenol A 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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Other Bisphenol A Production Cost Reports
BPA from Acetone and Phenol (Ion-Exchange Resin Catalyst)
This report presents a techno-economic analysis of Bisphenol A (BPA) production in the United States, via a process similar to Dow's QBIS technology. In this process, BPA is produced by the reaction of acetone with phenol catalyzed by a cation-exchange resin.
Details: 200 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $799 USD
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