Commodity Production Costs Report
Polycarbonate Production from BPA, Phenol and Methanol
Polycarbonate Plant Capital & Operating Cost Analysis | United States | Q2 2025
It presents the economics of Polycarbonate (PC) production from bisphenol A (BPA), phenol and methanol in the United States. Initially, methanol is carbonylated with carbon monoxide, producing dialkyl carbonate which are reacted with phenol to form diphenyl carbonate. It is then transesterified with BPA and polycondensed to generate PC.
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.
Product
Polycarbonate. Polycarbonate (a.k.a. PC) is a thermoplastic polymer/resin, derived from diphenyl carbonate, phosgene and bisphenol A. The polymer is easily molded and thermoformed, and for that, along with its properties, polycarbonates are among the most used plastics in industry. Polycarbonate has a high impact and dielectric strength, heat resistance, it is noncorrosive and extremely dimensionally stable. Depending on the grade, the resulting material is translucent, so PC has been used as a substitute to glass, although it is not its primary use, due to PC being more expensive than polymethyl methacrylate (acrylic). The main uses of PC are in the construction industry and as engineering materials. Because of their unusual properties (e.g. toughness, clarity), Polycarbonates figure among the top engineering thermoplastics.
Raw Materials
BPA. Bisphenol A is a high volume production organic compound, synthesized from phenol and acetone. It has been produced in commercial since the 1950's and is mostly used in the production of polycarbonate plastic and epoxy resins. Nowadays its use in products with contact with food has been decreasing, mostly in the United States, due to a rising concern on the negative health effects it might cause.
Methanol. Methanol is a simple alcohol used as a solvent, antifreeze, and a feedstock for producing formaldehyde, acetic acid, and methyl tert-butyl ether (MTBE). It is also an alternative fuel in various energy applications. Methanol is produced from synthesis gas and is stored as a liquid. In addition to its widespread use in chemicals and fuels, methanol is increasingly used in the production of biodiesel and fuel cells, highlighting its role in renewable energy technologies.
Phenol. Phenol is an aromatic compound primarily used in the production of phenolic resins and bisphenol-A (BPA), which is a precursor for polycarbonate plastics and epoxy resins. It is also used in herbicides, pharmaceuticals, and adhesives. Phenol is produced from cumene via the cumene hydroperoxide process and is stored as a crystalline solid or liquid. Its high reactivity with formaldehyde in resin formation makes it critical in producing durable materials for construction and electronics.
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Professional report based on Q2 2025 economic data, ensuring timely evaluations.
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Polycarbonate 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 Polycarbonate 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 Polycarbonate 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 Polycarbonate 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 Polycarbonate Production Cost Reports
Polycarbonate Production from BPA and DPC
This study presents the economics of Polycarbonate (PC) production from bisphenol A (BPA) and diphenyl carbonate (DPC) in the United States, via a typical melt process. In this process, DPC is transesterified with BPA to form PC and phenol as by-product. The reaction is conducted in oligomerization and polymerization.
Details: 200 kta United States-based plant | Q2 2025 | 107 pages | Issue B | From $799 USD
Polycarbonate Production from BPA, Phenol and Phosgene
It presents the economics of Polycarbonate (PC) production from bisphenol A (BPA), phenol and phosgene in the United States, via a typical melt process integrated with a diphenyl carbonate (DPC) production unit. Initially, phenol is phosgenated to produce DPC. Then, the DPC is transesterified with BPA and polycondensed to generate PC.
Details: 150 kta United States-based plant | Q2 2025 | 107 pages | Issue H | From $1,199 USD
Isosorbide Polycarbonate Production
This report examines the costs related to Isosorbide Polycarbonate production from glucose and ethylene oxide in the USA, using a melt polymerization process similar of isosorbide and diphenyl carbonate (DPC) to the one proposed by Mitsubishi Chemical. Isosorbide is produced from glucose and DPC from ethylene oxide. Ethylene glycol is generated as a by-product.
Details: 150 kta United States-based plant | Q2 2025 | 107 pages | Issue C | From $1,499 USD
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Other Related 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 | Q2 2025 | 107 pages | Issue B | From $799 USD
Phenol Production from Toluene
This study reviews the economics of a process producing Phenol from toluene. Initially, toluene is oxidized to benzoic acid intermediate in liquid phase, which is then converted to Phenol in the liquid phase in the presence of cupric and magnesium benzoates. The economic analysis presented assumes a plant constructed in the United States.
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Methanol Production from Naphtha
This report presents an economic analysis of Methanol production from naphtha in the United States. In this process, naphtha undergoes partial oxidation producing syngas, which is then converted to Methanol.
Details: 1700 kta United States-based plant | Q2 2025 | 107 pages | Issue D | From $1,199 USD
Methanol Production from Refuse-Derived Fuels
This report provides the economics of Methanol from refuse-derived fuels (RdF) for a waste-to-methanol (WtM) process in the United States. In this process, RdF is first gasified to syngas, which is then converted to Methanol.
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