Commodity Production Costs Report
Polycarbonate Production from Phenol & Acetone
Polycarbonate Plant Capital & Operating Cost Analysis | United States | Q1 2026
This report presents the economics of Polycarbonate (PC) production from phenol, acetone and phosgene. The process examined is a typical interfacial process. In this process, the Polycarbonate plant is integrated with a plant for bisphenol A (BPA) production from phenol and acetone. In this process, BPA is reacted with phosgene at the interface of a two-phase mixture. The carbonate oligomers produced are then polycondensed to Polycarbonate resin.
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
Acetone. Acetone, also known as 2-propanone, is the simplest ketone. It is used as solvent for a wide range of organic compounds (e.g. oils, fats, resins, waxes and gums). It is also used as feedstock for the production of several chemicals, such as methyl methacrylate, bisphenol A, and methyl isobutyl ketone. The main source of acetone is the process for phenol production from cumene, which generates acetone as by-product at an approximate ratio for 0.6 kg of acetone per kg of phenol. Industrial consumers of acetone usually receive shipments in large containers made of carbon steel, tank trucks made of stainless steel or aluminum, or rail tank cars made of carbon steel or aluminum. International shipments by sea are usually made in steel barges and amount at least 2,000 metric tons.
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.
Phosgene. Phosgene is a highly toxic gas used industrially in the production of isocyanates and polycarbonates, essential precursors for polyurethane foams and plastics. It facilitates the introduction of carbonyl groups in organic synthesis. Phosgene is produced by reacting carbon monoxide with chlorine gas and is handled under strict safety protocols due to its toxicity. Its reactivity enables efficient manufacturing processes in polymer and chemical industries.
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Professional report based on Q1 2026 economic data, ensuring timely evaluations.
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What You Get in Each Report
Behind every cost estimate is a structured view of the process, its requirements, and the economics of building and operating the plant.
Plant Capital Cost Summary
Capital cost required to build the plant examined.
Plant Capital Cost Details
Fixed capital (ISBL, OSBL, and owner's cost), working capital, and additional capital requirements.
Plant Cost Breakdowns
Process unit (ISBL) and infrastructure (OSBL) costs, plus a plant cost breakdown by discipline.
Operating Costs Summary
Variable costs and the total operating cost of the plant studied.
Operating Cost Details
Utilities costs, operating fixed costs, and depreciation.
Plant Capacity Assessment
Capital investment and operating costs compared across different plant capacities.
Production Process Information
Block flow diagram, with descriptions of the process unit (ISBL) and site infrastructure (OSBL).
Process Consumptions
Raw materials and utilities consumption, by-product credits, and labor requirements.
Process Diagrams
Process flow diagrams (PFD), equipment list, and industrial site configuration.
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
Preview our Production Cost Reports
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 | Q1 2026 | 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 | Q1 2026 | 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 | Q1 2026 | 107 pages | Issue C | From $1,499 USD
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Other Related Production Cost Reports
Acetone Production from Isopropanol
This feasibility study presents the economics of Acetone production from isopropanol using a liquid phase dehydrogenation process. The economic analysis presented in the study assumes a plant located in the United States.
Details: 30 kta United States-based plant | Q1 2026 | 107 pages | Issue B | From $999 USD
Acetone Production from Propylene (Single-Step Process)
This report approaches the economics of Acetone production from propylene in the United States. In the process examined, a direct propylene oxidation is carried out in the presence of palladium chloride and copper chloride, yielding Acetone.
Details: 80 kta United States-based plant | Q1 2026 | 107 pages | Issue C | From $999 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.
Details: 50 kta United States-based plant | Q1 2026 | 107 pages | Issue D | From $1,199 USD
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