Commodity Production Costs Report
Solution Styrene Butadiene Rubber Production
Styrene Butadiene Rubber Operating Costs & Plant Construction Costs
This report presents the economics of SBR production starting from butadiene and styrene in the United States. It approaches a continuous process for producing a solution SBR grade. In this process, the anionic copolymerization of styrene and butadiene is carried out in the presence of cyclohexane solvent.
The report provides a comprehensive study of Styrene Butadiene Rubber production and related Styrene Butadiene Rubber production cost, covering three key aspects: a complete description of the Styrene Butadiene Rubber production process examined; an in-depth analysis of the related Styrene Butadiene Rubber plant capital cost (Capex); and an evaluation of the respective Styrene Butadiene Rubber plant operating costs (Opex).
The Styrene Butadiene Rubber 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 Styrene Butadiene Rubber 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 Styrene Butadiene Rubber 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) Polymerization; and (2) Purification.
Polymerization. The butadiene and styrene monomers are initially treated for the removal of impurities and dried since moisture could inhibit the polymerization. This mixture is fed with butyl lithium in cyclohexane solution in reactor. The anionic copolymerization is carried out continuously under a nitrogen atmosphere, in two stirred tank reactors operating in series to avoid inhibition effects of air. Potassium tert-butoxide is also fed to promote random copolymerization. The effluent from the polymerization train, a polymer slurry, is routed to purification.
Purification. The reaction termination is accomplished by mixing stopping agents with the polymer solution from the reactors train, which destroy the catalyst. The mixture is fed to a vessel where part of cyclohexane is flashed off from the slurry. The solvent is condensed and is passed through a couple of columns for the removal of residual impurities, before being recycled to the beginning of the process. The polymer solution is mixed with antioxidants, homogenized and then steam-stripped, for the removal of residual solvent, which is also purified and recycled. The crumb slurry is then pumped to the finishing steps: it is dried, pressed into bales, weighted, film-wrapped, and boxed.
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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 Styrene Butadiene Rubber 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 Styrene Butadiene Rubber 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 Styrene Butadiene Rubber 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 Styrene Butadiene Rubber 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 Styrene Butadiene Rubber Production Cost Reports
Solution Styrene Butadiene Rubber from Styrene and Butane
This report presents the economics of SBR production from n-butane and styrene. In this process, 1,3-Butadiene is initially produced from n-butane via a dehydrogenation process that is similar to Lummus Catadiene. Then, styrene and butadiene are polymerized via a typical continuous solution process for producing a solution SBR grade.
Details: 120 kta United States-based plant | Q3 2024 | 107 pages | Issue F | From $1,499 USD
High Solids Styrene Butadiene Latex Production
This report presents the economics of high solids content SBR Latex production starting from butadiene and styrene. The analysis, based on a plant located in the United States, approaches a typical cold emulsion process. For generating a high solids latex with high butadiene content, the obtained low solids latex is further concentrated after polymerization.
Details: 160 kta United States-based plant | Q3 2024 | 107 pages | Issue C | From $799 USD
Low Solids Styrene Butadiene Latex Production
This report targets SBR Latex production in the United States via a typical cold emulsion polymerization process. The main product generated is a low solids content SBR Latex with high styrene content.
Details: 160 kta United States-based plant | Q3 2024 | 107 pages | Issue D | From $799 USD
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