Commodity Production Costs Report
Styrene Production from Polystyrene Waste
Styrene Operating Costs & Plant Construction Costs
This report assesses the economics of Styrene production from polystyrene waste via pyrolysis in the United States. In this process, polystyrene waste is submitted to pyrolysis in a fluidized bed reactor. The pyrolysis gas is then sent to a distillation section where styrene is recovered along with toluene and fuel oil.
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): ?
Products
Styrene. Styrene is a largely available commodity generally produced from ethylbenzene by several means. One of the commercial routes for styrene production relies on the alkylation of benzene with ethylene for generating the ethylbenzene, which is then dehydrogenated to styrene in vapor phase with steam.
Toluene. Toluene (also known as Methylbenzene) is an aromatic hydrocarbon mainly used as an industrial feedstock and as solvent. A significant part of toluene production is blended directly into gasoline pools. Other major use of this chemical is in the manufacture of the more valuable benzene, through hydrodealkylation. Most of toluene is produced via catalytic reforming of refinery streams (C6–C9 naphthas), along with benzene, xylenes, and C9-aromatics.
Fuel Oil. Fuel Oil is a heavy petroleum product primarily used for power generation, shipping, and industrial heating. It is characterized by its high energy content and viscosity, making it suitable for large-scale combustion processes. Fuel oil is obtained from the residual fractions of crude oil after refining and is stored in tanks as a liquid. It is typically used in low-speed marine engines and industrial boilers, where its slow-burning properties allow for efficient energy transfer over long periods.
Raw Material
Polystyrene Scrap. Polystyrene scrap is recycled plastic waste primarily derived from packaging materials and disposable containers. It is processed into new plastic products or used as an alternative fuel source. Polystyrene scrap is cleaned, melted, and reprocessed into pellets for manufacturing. Despite its low recycling rate, innovations in chemical recycling are increasing its potential reuse in industrial applications.
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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 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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Other Styrene Production Cost Reports
Styrene Production from Methanol & Toluene
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.
Details: 750 kta United States-based plant | Q3 2024 | 107 pages | Issue E | From $799 USD
Styrene Production from Propylene & Ethylbenzene
This study presents the economics of Styrene production from chemical grade (CG) propylene and ethylbenzene in the United States. The process examined is a Propylene Oxide/Styrene Monomer (POSM) technology similar to the one owned by LyondellBasell. This process involves ethylbenzene oxidation, epoxidation, hydrogenation and dehydration steps.
Details: 850 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $1,199 USD
Styrene Production from Ethane & Benzene (H2 as Co-Product)
This report presents the economics of Styrene production from ethane and benzene in the United States, with pure hydrogen as by-product. In this report, ethylbenzene (EB) is first generated from benzene and recycled ethylene. Then, fresh ethane and the EB are dehydrogenated to form ethylene and Styrene. The process analyzed is based on concepts proposed in patents issued to Dow and Snamprogetti.
Details: 750 kta United States-based plant | Q3 2024 | 107 pages | Issue C | From $1,199 USD
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Other Related Production Cost Reports
Solution Styrene Butadiene Rubber Production
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.
Details: 120 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $799 USD
Emulsion Styrene Butadiene Rubber Production
This report presents the economics of SBR production starting from butadiene and styrene. The analysis encompasses a plant located in the United States, employing a typical cold emulsion process for generating a non-oil extended, non-staining grade of emulsion SBR (similar to 1502). In this process, an emulsion comprising water, styrene and butadiene is polymerized into a latex, which is then coagulated to form the SBR.
Details: 140 kta United States-based plant | Q3 2024 | 107 pages | Issue A | From $799 USD
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