Commodity Production Costs Report

Expandable Polystyrene Production

Polystyrene Operating Costs & Plant Construction Costs

150 kta United States-based plant | 107 Pages | Issue C | Q3 2024
Starting at $799 USD | See Report Editions Prices

This study presents the economics of Expandable Polystyrene (EPS) production from styrene in the United States, via a typical batch suspension polymerization process. The tiny spheres of EPS are impregnated with a physical blowing agent.

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

The Polystyrene 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 Polystyrene 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 Polystyrene 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): ?

Polystyrene Production Cost Report Process Schematic

The process under analysis comprises two major sections: (1) Polymerization; and (2) Polymer separation and finishing.

Polymerization. Styrene monomer feed stream, demineralized water, polymerization initiators, blowing agent, suspending agents and additives are supplied to a stirred reactor. The reaction occurs substantially in the liquid phase, in styrene droplets dispersed in water, used as diluent. After polymerization ignition, the heat from the exothermic reaction is removed by means of cooling water. The polymerization occurs according to a time-temperature profile, under agitation. As the polymer is formed, it precipitates out of the reaction medium, floating in the liquid monomer phase as polymer beads. The polymerization is interrupted when the conversion of styrene to Polystyrene reaches 100% and the polymer slurry is fed to a hold tank.

Polymer separation and finishing. The polymer slurry is then passed through a centrifuge, in such a way that Polystyrene beads containing only residual moisture are obtained. At this point, the Polystyrene beads are conveyed to a drying step. The Polystyrene beads obtained are screened, coated, packed and sent to storage facilities.

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Features
  • Production Process Information
  • Process Consumptions
  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
  • Production Costs Datasheet
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 80 Pages | 22 Tables | 9 Images

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Table of Contents


Features
  • Production Process Information
  • Process Consumptions
  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
  • Production Costs Datasheet
  • Plant Capital Cost Details
  • Operating Cost Details
  • See All Features

 90 Pages | 28 Tables | 13 Images

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Updated with Q3 2024 Data

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Table of Contents


Features
  • Production Process Information
  • Process Consumptions
  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
  • Production Costs Datasheet
  • Plant Capital Cost Details
  • Operating Cost Details
  • Plant Cost Breakdowns
  • Plant Capacity Assessment
  • Process Flow Diagrams
  • Costs in Different Countries Add-on
  • See All Features

  • 107 Pages | 34 Tables | 22 Images
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  • Updated with Q3 2024 Data
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Content Highlights

Plant Capital Cost Summary

Summary outlining the capital cost required for building the Polystyrene 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 Polystyrene 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 Polystyrene 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 Polystyrene 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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