Polycarbonate Production from BPA and DPC

This report presents the economics of Polycarbonate (PC) production from bisphenol A (BPA) and diphenyl carbonate. The process examined is a typical melt process. This process is based on the transesterification reaction of BPA with diphenyl carbonate to produce Polycarbonate. During the reaction, phenol is removed and obtained as a by-product.

The report provides a comprehensive study of Polycarbonate production and related Polycarbonate production cost, covering three key aspects: a complete description of the Polycarbonate production process examined; an in-depth analysis of the related Polycarbonate plant capital cost (Capex); and an evaluation of the respective Polycarbonate plant operating costs (Opex).

The Polycarbonate 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 Polycarbonate 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 Polycarbonate plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.