Commodity Production Costs Report
Liquid and Solid Epoxy Resins Production
Epoxy Resins Operating Costs & Plant Construction Costs
This report presents the economics of Liquid and Solid Epoxy Resins production from epichlorohydrin and bisphenol A (BPA) considering a United States-based facility. In this process, epichlorohydrin and BPA are reacted in the presence of an aqueous sodium hydroxide solution to form Liquid Epoxy Resin. The resulting resin is purified and further reacted with BPA to produce the Solid Epoxy Resin. Part of the Liquid Epoxy Resin obtained is also sold as co-product.
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 is divided into two main areas: (1) Liquid Epoxy Resin production; and (2) Solid Epoxy Resin production.
Liquid Epoxy Resin production. Bisphenol A and epichlorohydrin are mixed with caustic soda in stirred tank reactors where a caustic coupling reaction occurs yielding an intermediate. This compound along with more caustic soda, are fed to another set of stirred reactors, where a dehydrochlorination reaction occurs finally yielding a mixture of diglycidyl ether bisphenol A, the Liquid Epoxy Resin, and sodium chloride. The crude resin is dissolved in methyl isobutyl ketone (MIBK) and the formed salt precipitates. The mixture is centrifuged and the salt is separated and discarded. The liquid phase is then passed through an evaporator where the solvent is volatilized leaving pure Liquid Epoxy Resin that is partially sent for storage as a co-product and partially sent to the advancement reactor.
Solid Epoxy Resin production. The produced Liquid Resin, bisphenol A and catalyst are fed to stirred tank reactors, where the resin is further reacted in a chain-extension reaction that produces a viscous melt of high molecular weight resin. This melt is then cooled and packed as the Solid Epoxy Resin 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
Epoxy Phenol Novolac Resin Production
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.
Details: 3 kta United States-based plant | Q3 2024 | 107 pages | Issue D | From $799 USD
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
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