Commodity Production Costs Report

Styrene Production from Methanol & Toluene

Styrene Operating Costs & Plant Construction Costs

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

This report analyses the economics of Styrene production from methanol and toluene in the United States. The process evaluated is similar to Exelus Styrene Monomer Technology (ExSyM) technology. In this process, toluene is submitted to alkylation with methanol over zeolite catalyst, yielding styrene.

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

The Styrene 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 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 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): ?

Styrene Production Cost Report Process Schematic

The process under analysis comprises the following major sections: (1) alkylation; (2) styrene separation and (3) purification.

* Alkylation. Initially, fresh and recycled toluene and methanol are vaporized, superheated, and fed to alkylation reactors. The reaction is carried out in a fixed-bed reactor at around 400 - 425 °C at atmospheric pressure in the presence of a modified zeolite catalyst. The effluent from the alkylation, containing Styrene, ethylbenzene, hydrogen, carbon monoxide and unconverted methanol and toluene, is then directed to separation steps downstream.

* Styrene separation. The effluent from the alkylation step is cooled, partially condensed, and fed to a settling drum. Vapors are disengaged from the liquid phase, compressed, cooled and passed through an absorber/stripper system, for the recovery of residual aromatics which are recycled. The aqueous phase from the settling drum is fed to a distillation column, in which unconverted methanol and dissolved trace hydrocarbons are recovered. Water withdrawn from column bottom is discharged. The organic phase from the settling drum is directed to purification steps downstream.

* Purification. The organic phase from Styrene separation is mixed with dinitrophenols, which act as inhibitor to lessen polymer formation throughout distillation steps downstream, carried out under vacuum. In a first distillation step, unreacted toluene is separated from the Styrene stream and recycled to the alkylation reaction. In a subsequent distillation step, Styrene is separated from ethylbenzene, which is sold as by-product. Finally, Styrene is purified from residual impurities – mainly C9 aromatic compounds – in a last distillation step.

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  • 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


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  • Production Process Information
  • Process Consumptions
  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
  • Production Costs Datasheet
  • Plant Capital Cost Details
  • Operating Cost Details
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 90 Pages | 28 Tables | 13 Images

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Table of Contents


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  • 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
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  • 107 Pages | 34 Tables | 22 Images
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Content Highlights

Plant Capital Cost Summary

Summary outlining the capital cost required for building the Styrene 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 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 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 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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Details: 750 kta United States-based plant | Q3 2024 | 107 pages | Issue D | From $1,199 USD

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