Emulsion Styrene Butadiene Rubber Production
Styrene Butadiene Rubber Production Costs Report | Issue A | Q4 2024
| Report Details |
| 140 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 140 kta (kilo metric ton per annum) United States-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.
Report Abstract
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.
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.
Process Schematic
The process under analysis comprises three major sections: (1) Polymerization; (2) Monomers recovery; and (3) Coagulation,drying and finishing.
Polymerization. Styrene and butadiene are mixed with emulsifier and demineralized water to form the emulsion that will be fed to the polymerization. Polymerization is comprised of jackted CSTR-type reactors connected in series. To keep the low reaction temperature, all reactors are cooled using ammonia refrigeration. Downstream, a shortstop agent is mixed with the emulsion in order to stop reaction at the desired conversion, avoiding gel formation. The shortstopped latex is sent to monomers recovery section.
Monomers recovery. The latex generated in polymerization reactors is directed to blow down tanks and subsequently flashed to recover unreacted butadiene. Residual butadiene vapors are sent to a butadiene recovery step, while the degassed latex is pumped to a steam stripping column. In butadiene recovery, water is removed from the stream and recovered butadiene is recycled to the Butadiene Plant for butenes separation, so the recovered butadiene can be reused in the eSBR plant. In the steam stripping column, residual styrene monomer is stripped by contacting the latex with steam entering the column bottom. Stripped styrene is recycled to the polymerization, while the latex is transferred to the coagulation.
Coagulation, drying and finishing. In the coagulation step, the latex coagulates and becomes small crumbs suspended in water. The coagulated crumb is then dried in continuous belt dryers. After drying, the rubber is pressed into bales, weighted, film-wrapped, and boxed.
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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
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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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