Commodity Production Costs Report

Isophthalic Unsaturated Polyester Production

Unsaturated Polyester Resin Operating Costs & Plant Construction Costs

70 kta United States-based plant | 107 Pages | Issue A | Q3 2024
Starting at $999 USD | See Report Editions Prices

This report presents the economics of Isophthalic Unsaturated Polyester production from maleic anhydride, isophthalic acid, propylene glycol and styrene using a two-stage batch process located in the United States. In the first stage, the glycol and isophthalic acid react to produce a cleat melt. Maleic anhydride is added subsequently and the resin is completed.

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

The Unsaturated Polyester Resin 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 Unsaturated Polyester Resin 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 Unsaturated Polyester Resin 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): ?

Unsaturated Polyester Resin Production Cost Report Process Schematic

The process under analysis comprises three major sections: (1) Esterification; (2) Cross-linking; and (3) Glycols recovery.

Esterification. This first step involves the polycondensation between a combination of isophthalic anhydride, maleic anhydride and propylene glycol in a process comprised of two-stages. In the first stage, isophthalic acid and propylene glycol react, producing a clear melt, while the second stage comprises the addition of maleic anhydride. The esterification reactor is equipped with stirrers and a cooling and heating internal coil. It is fed with nitrogen to generate an inert blanket. The high temperatures in the reactor cause the evaporation of the glycols and the water generated in the reaction.

Cross-linking. The cross-linking is carried out in a different vessel, where the polycondensation product is dissolved in styrene and the reaction takes place. In this reaction, the vinyl radical in styrene monomer reacts with the unsaturation in the polyester chains, thus linking different chains. Also during this step, promoters are added to initiate the copolymerization and inhibitors are added to avoid polymer premature gelation. At last, the final product is charged into drums and stored in a warehouse.

Glycols recovery. A water separation column receives the overhead vaporous glycol-water mixture from the reactor. The column top temperature is kept at 100 - 105 °C in such a way that the column overhead product contains only water, which is further routed to a condenser and discarded. The glycol-rich bottom product is recycled to the reactor.

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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


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
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 90 Pages | 28 Tables | 13 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
  • 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 Unsaturated Polyester Resin 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 Unsaturated Polyester Resin 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 Unsaturated Polyester Resin 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 Unsaturated Polyester Resin 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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