ICC - Is Bespoken: 0

ICC - Main References: ?

ICC - Issue: A

ICC - Volume: 48

ICC - Report ID: 048-A

ICC - Report Location: United States

ICC - Is Popular: 0

ICC - Is Developed: 1

ICC - Title: BPA from Acetone and Phenol (Hydrogen Chloride Catalyst)

ICC - Show Overview: 1

ICC - Report Location ID: 1

ICC - Plant Capacity Unit ID: 14

ICC - Volume Reports List: 048-B

ICC - Related Reports List: 186-B,045-B,186-C,045-A,200-B,200-A

ICC - Report Location Code: USA

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ICC - Plant Capacity Unit Name: kilo metric ton per annum

ICC - Plant Capacity Unit Short Name: kta

ICC - Process Overview Image: //cdn.intratec.us/images/icc/process-overview/048-A.jpg

ICC - Process Overview Text: ProductBPA. Bisphenol A is a high volume production organic compound, synthesized from phenol and acetone. It has been produced in commercial since the 1950's and is mostly used in the production of polycarbonate plastic and epoxy resins. Nowadays its use in products with contact with food has been decreasing, mostly in the United States, due to a rising concern on the negative health effects it might cause.Raw MaterialsChemicals. Acetone. Acetone, also known as 2-propanone, is the simplest ketone. It is used as solvent for a wide range of organic compounds (e.g. oils, fats, resins, waxes and gums). It is also used as feedstock for the production of several chemicals, such as methyl methacrylate, bisphenol A, and methyl isobutyl ketone.The main source of acetone is the process for phenol production from cumene, which generates acetone as by-product at an approximate ratio for 0.6 kg of acetone per kg of phenol.Industrial consumers of acetone usually receive shipments in large containers made of carbon steel, tank trucks made of stainless steel or aluminum, or rail tank cars made of carbon steel or aluminum. International shipments by sea are usually made in steel barges and amount at least 2,000 metric tons.Phenol. Phenol, also known as hydroxybenzene, is an aromatic compound, comprised of an aromatic ring attached to a hydroxyl group. The major route for phenol production is based on cumene oxidation. Phenol is mainly employed in the manufacturing of bisphenol A (BPA), phenolic resins, Caprolactam and analine.

ICC - Process Schematic Image: //cdn.intratec.us/images/icc/process-schematics/048-A.jpg

ICC - Process Schematic Text: The process under analysis comprises three major sections: (1) Condensation reaction; (2) Purification and (3) Finishing.Condensation reaction. Phenol and acetone along with hydrogen chloride are fed to two agitated jacketed reactors in series. In the reactors, the condensation reaction between phenol and acetone occurs, producing a crude product with Bisphenol A isomers. The crude product is subsequently passed through two distillation columns for recovering hydrogen chloride and unreacted phenol to be recycled to the process. Distilled hydrochloric acid is fed to a recovery area for removal of water before recycling back to the reactor.Purification. The bottom stream from the phenol column is fed to a distillation column for the removal of a portion of the o,p-BPA isomer, some impurities, and residual phenol. The column's overhead stream containing the removed compounds is returned to the reactor while the bottom stream is sent to a thin-film evaporator, in which Bisphenol A is separated from high boiling by-products and tars. The Bisphenol A stream is then mixed with benzene and fed to a crystallizer, where the temperature is reduced and the desired p,p-BPA isomer is precipitated. The resulting slurry passes through a centrifuge and the Bisphenol A crystals are dryed.Finishing. The dried Bisphenol A cystals are melted, prilled and then classified; the oversize solids are returned for further processing, while the Bisphenol A product is directed to packing. Polycarbonate grade Bisphenol A prills with a purity of 99.5 wt% is obtained as the final product.

ICC - Short Description: This report presents the economics of Bisphenol A (BPA) production in the United States via a condensation reaction of acetone with phenol catalyzed by hydrogen chloride.

ICC - Main Product: Bisphenol A

ICC - Plant Capacity: 30.00

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BPA from Acetone and Phenol (Hydrogen Chloride Catalyst)

Bisphenol A Production Costs Report | Issue A | Q4 2024

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30 kta United States-based plant | Q4 2024 | 107 pages

This report presents a cost analysis of a 30 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 Bisphenol A (BPA) production in the United States via a condensation reaction of acetone with phenol catalyzed by hydrogen chloride.

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

The Bisphenol A 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 Bisphenol A 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 Bisphenol A plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.

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Plant Capital Cost Summary

Summary outlining the capital cost required for building the Bisphenol A 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 Bisphenol A 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 Bisphenol A 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 Bisphenol A 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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BPA from Acetone and Phenol (Ion-Exchange Resin Catalyst)

This report presents a techno-economic analysis of Bisphenol A (BPA) production in the United States, via a process similar to Dow's QBIS technology. In this process, BPA is produced by the reaction of acetone with phenol catalyzed by a cation-exchange resin.

Details: 200 kta United States-based plant | Q4 2024 | 107 pages | Issue B From $799 USD

The cost analyses presented in this report target a 200 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

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Phenol Production from Benzene and Hydrogen Peroxide

This study presents the economics of Phenol production from benzene and hydrogen peroxide in the United States using a process similar to the one proposed by the Council of Scientific and Industrial Research. In this process, benzene is directly oxidized with hydrogen peroxide to Phenol, using a vanadyl pyrophosphate catalyst.

Details: 50 kta United States-based plant | Q4 2024 | 107 pages | Issue A From $999 USD

The cost analyses presented in this report target a 50 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

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Phenol Production from Cumene

This report presents a feasibility analysis of Phenol production from cumene in the United States using a typical hydroperoxidation process. In this process, cumene is oxidized with air to cumene hydroperoxide, which is then cleft to produce Phenol and acetone.

Details: 200 kta United States-based plant | Q4 2024 | 107 pages | Issue B From $799 USD

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Acetone Production from Isopropanol

This feasibility study presents the economics of Acetone production from isopropanol using a liquid phase dehydrogenation process. The economic analysis presented in the study assumes a plant located in the United States.

Details: 30 kta United States-based plant | Q4 2024 | 107 pages | Issue B From $999 USD

The cost analyses presented in this report target a 30 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

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Acetone Production from Propylene (Single-Step Process)

This report approaches the economics of Acetone production from propylene in the United States. In the process examined, a direct propylene oxidation is carried out in the presence of palladium chloride and copper chloride, yielding Acetone.

Details: 80 kta United States-based plant | Q4 2024 | 107 pages | Issue C From $999 USD

The cost analyses presented in this report target a 80 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

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Polycarbonate Production from BPA and Phosgene

This report presents the economics of Polycarbonate (PC) production from bisphenol A (BPA) and phosgene in the United States, via a typical interfacial process. In this process, BPA, dissolved in a caustic soda solution, is reacted with phosgene, in an organic solution, at the interface of the two phases. The carbonate oligomers produced are then polycondensed to Polycarbonate.

Details: 200 kta United States-based plant | Q4 2024 | 107 pages | Issue A From $799 USD

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Polycarbonate Production from BPA and DPC

This study presents the economics of Polycarbonate (PC) production from bisphenol A (BPA) and diphenyl carbonate (DPC) in the United States, via a typical melt process. In this process, DPC is transesterified with BPA to form PC and phenol as by-product. The reaction is conducted in oligomerization and polymerization.

Details: 200 kta United States-based plant | Q4 2024 | 107 pages | Issue B From $799 USD

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BPA from Acetone and Phenol (Hydrogen Chloride Catalyst)

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Plant Capital Cost Summary

Plant Capital Cost Details

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Operating Cost Details

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Production Process Information

Process Consumptions

Process Diagrams

BPA from Acetone and Phenol (Ion-Exchange Resin Catalyst)

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Phenol Production from Benzene and Hydrogen Peroxide

Phenol Production from Cumene

Acetone Production from Isopropanol

Acetone Production from Propylene (Single-Step Process)

Polycarbonate Production from BPA and Phosgene

Polycarbonate Production from BPA and DPC

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