Commodity Production Costs Report
Polyether Polyurethane from TDI and Polyether Triol (Typical Foaming)
Polyurethane Operating Costs & Plant Construction Costs
This report examines the costs related to Flexible Slabstock Polyether Polyurethane production from toluene diisocyanate (TDI) and a polyether triol in the United States, via a typical foaming process.
The report provides a comprehensive study of Polyurethane production and related Polyurethane production cost, covering three key aspects: a complete description of the Polyurethane production process examined; an in-depth analysis of the related Polyurethane plant capital cost (Capex); and an evaluation of the respective Polyurethane plant operating costs (Opex).
The Polyurethane 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 Polyurethane 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 Polyurethane 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): ?
The process under analysis comprises two major sections: (1) Foaming and (2) Finishing.
Foaming. A polyether triol solution, toluene diisocyanate (TDI), and water, as well as other chemicals (e.g., catalyst, CO2, and additives), are fed into the first section of a foaming equipment – the mixing chamber. They are thoroughly mixed and directed to an inclined conveyor belt, through an injector. There, the reaction effectively takes place: TDI reacts with the polyether triol, producing a rectangular Polyurethane slab. Finally, in the last part of Foaming equipment, it is air-cooled and directed to Finishing steps.
Finishing. After Foaming, Flexible Slabstock Polyurethane is sent to curing, for about 12 hours. The slabs are placed in curing storage facilities, where they finish cooling down and reach the expected properties. Then, Polyurethane is directed to Finishing steps, in which it is cut and packed.
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Professional report based on Q3 2024 economic data, ensuring timely evaluations.
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Polyurethane 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 Polyurethane 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 Polyurethane 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 Polyurethane 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 Related Production Cost Reports
Toluene Diisocyanate from Toluene (Gas-Phase Phosgenation)
This report presents the economics of TDI production from toluene and chlorine via a process similar to the Bayer Gas-Phase Phosgenation (GPP) technology in the United States. Initially, toluene is dinitrated to dinitrotoluene (DNT). Then, DNT is hydrogenated to toluenediamine (TDA). Finally, TDA reacts with phosgene in gas phase to produce TDI. The phosgene used is generated from chlorine in an on-site unit.
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