Commodity Production Costs Report
Polyacrylonitrile Production
Polyacrylonitrile Operating Costs & Plant Construction Costs
This report presents a techno-economic analysis of Polyacrylonitrile (PAN) Precursor production in the United States via aqueous dispersion polymerization of acrylonitrile with methyl acrylate comonomer followed by transformation steps to become a fiber.
The report provides a comprehensive study of Polyacrylonitrile production and related Polyacrylonitrile production cost, covering three key aspects: a complete description of the Polyacrylonitrile production process examined; an in-depth analysis of the related Polyacrylonitrile plant capital cost (Capex); and an evaluation of the respective Polyacrylonitrile plant operating costs (Opex).
The Polyacrylonitrile 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 Polyacrylonitrile 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 Polyacrylonitrile 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 four major sections: (1) Polymerization; (2) Pelletizing; (3) Wet spinning; and (4) After-treatment.
Polymerization. Initially, a mixture of acrylonitrile, methyl acrylate and itaconic acid is fed continuously to a continuous stirred-tank reactor (CSTR) where the polymerization takes place. The reaction is initiated by feeding aqueous solutions of potassium persulfate (oxidizer), sulfur dioxide (reducing agent), ferrous iron (promoter), and sodium bicarbonate (buffering agent). The heat of polymerization is removed by water circulated in a reactor jacket. Next, an iron-chelating agent is added to the reactor overflow, where it acts as a chain stopper for the polymerization. The reactor overflow, an aqueous slurry of polymer particles, is fed to a monomer-separation column, in which unreacted monomer is steam-stripped from the slurry. The monomers recovered are returned to the reactor.
Pelletizing. The polymer is pelletized, dried, ground and then converted to fiber through subsequent steps involving physicochemical transformations, as briefly described below.
Wet spinning. The polymer is dissolved in dimethylformamide (DMF), forming a dope. The dope is pumped through a spinneret into a precipitating bath, for the coagulation of the solution thread line into a highly swollen gel yarn.
After-treatment. The fiber is washed in countercurrent by hot water, for the removal of the solvent. The fiber is then stretched while passing over rollers with adjustable speed. The stretching imparts fiber strength. Subsequently, silicone is applied as an aqueous emulsion to the fiber, to act as lubricant and antistatic agent. The fiber passes through drum dryers for water removal. Tows are crimped by means of a stuffer box crimper. Crimping provides interflament cohesion across the tow and facilitates subsequent handling. Then the fiber is fed to an autoclave for a relaxation process that reduces the tendency for fibrillation and increases the fiber dimensional stability.
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Polyacrylonitrile 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 Polyacrylonitrile 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 Polyacrylonitrile 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 Polyacrylonitrile 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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