Commodity Production Costs Report
Epoxy Phenol Novolac Resin Production
Epoxy Resins Operating Costs & Plant Construction Costs
This report presents a techno-economic study of a process for Epoxy Phenol Novolac Resin production from phenol, formaldehyde and epichlorohydrin in a plant constructed in the United States. The process examined comprises two main steps: condensation of phenol and formaldehyde to produce phenol novolac resin; and (2) epoxidation of the phenol novolac resin with epichlorohydrin to form Epoxy Phenol Novolac Resin.
The report provides a comprehensive study of Epoxy Resins production and related Epoxy Resins production cost, covering three key aspects: a complete description of the Epoxy Resins production process examined; an in-depth analysis of the related Epoxy Resins plant capital cost (Capex); and an evaluation of the respective Epoxy Resins plant operating costs (Opex).
The Epoxy Resins 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 Epoxy Resins 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 Epoxy Resins 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 two major sections: (1) Phenol novolac resin production; and (2) Epoxy Phenol Novolac Resin production.
Phenol novolac resin production. Initially, phenol and formaldehyde are subjected to a condensation reaction, using oxalic acid as catalyst, yielding phenolic novolac resin. The reaction is carried out in batch mode, at 100 °C, under atmospheric pressure in a jacketed stirred tank reactor equipped with a reflux condenser. The reaction is exothermic, so the addition of formaldehyde is gradual to help control the temperature. The reaction ends with the depletion of formaldehyde and the water generated along with unreacted phenol are removed by evaporation and sent to a phenol recovery system.
Epoxy Phenol Novolac Resin production. In this section, the phenolic novolac resin is subjected to an epoxidation reaction with epichlorohydrin using caustic soda as catalyst, yielding Epoxy Phenol Novolac Resin. The reaction is carried out in batch mode, at 70 °C, under 0.2 bar pressure in a jacketed stirred tank reactor. The evaporated water and epichlorohydrin are sent to a decanter where the epichlorohydrin is separated to be recycled. Upon completion, the Epoxy Resin formed is washed, water and remaining unreacted epichlorohydrin are removed and liquid Epoxy Phenol Novolvac (EPN) Resin 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 Epoxy Resins 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 Epoxy Resins 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 Epoxy Resins 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 Epoxy Resins 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 Epoxy Resins Production Cost Reports
Liquid Epoxy Resin Production
In this report, epichlorohydrin and bisphenol A (BPA) are used in the production of Liquid Epoxy Resin (LER) only. The economic analysis considers a plant located in the United States. Epichlorohydrin and BPA are reacted in the presence of an aqueous sodium hydroxide solution to form Liquid Epoxy Resin.
Details: 130 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $799 USD
Solid Epoxy Resin Production
This report presents a feasibility analysis of Solid Epoxy Resin (SER) production from liquid epoxy resin (LER) and bisphenol A (BPA) in the United States. This process consists of a chain-extension reaction of liquid epoxy resin with bisphenol A, often referred to as the advancement or fusion process.
Details: 35 kta United States-based plant | Q3 2024 | 107 pages | Issue C | From $799 USD
Epoxy Cresol Novolac Resin Production
This study provides an economic analysis of Epoxy Cresol Novolac Resin production from epichlorohydrin and o-cresol for a plant located in the United States.
Details: 3 kta United States-based plant | Q3 2024 | 107 pages | Issue E | From $799 USD
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