Commodity Production Costs Report
Polycarbonate Production from BPA, Phenol and Phosgene
Polycarbonate Operating Costs & Plant Construction Costs
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.
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.
The process under analysis comprises four major sections: (1) DPC synthesis; (2) DPC purification; (3) Polymerization; (4) Polycarbonate finishing.
Diphenyl carbonate synthesis. Initially, phenol is reacted with phosgene to produce diphenyl carbonate (DPC). The phosgenation reaction is carried out in three fixed bed reactors filled with gamma-alumina connected in series. The product from phosgenation mainly containing phenol and diphenyl carbonate is directed to the DPC purification. The waste gas coming from the phosgenation, mostly containing HCl and inert gases, is fed to a HCl recovery unit, where hydrochloric acid with a concentration of 32 wt% is obtained as by-product.
DPC purification. The effluent from the DPC synthesis is fed to a set of distillation columns for the purification of diphenyl carbonate and recovery of unconverted phenol, which is recycled to the DPC synthesis.
Polymerization. Purified diphenyl carbonate, bisphenol A and sodium dihydrogen phosphite are mixed and heated to form a melt, which is subsequently fed to a oligomerization step, where low molecular weight oligomers are generated. The oligomers are directed to more severe conditions, then polymerization is completed in two CSTR operating in series. Polymerization is interrupted by addition of n-butyl tosylate, which deactivates the catalyst. Phenol and other by-products are continuously removed and sent to a distillation column, where phenol is withdrawn from overhead and recycled to the DPC synthesis.
Polycarbonate finishing. The polymer melt is filtered, and a mix of additives is added. The mixture is homogenized and pelletized. Finally, the Polycarbonate pellets are conveyed to homogenization system and fed to the packing system.
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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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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.
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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
Polycarbonate Production from BPA and Ethylene Oxide
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Details: 150 kta United States-based plant | Q2 2025 | 107 pages | Issue D | From $1,199 USD
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