BPA from Acetone and Phenol (Ion-Exchange Resin Catalyst)
Bisphenol A Production Costs Report | Issue B | Q4 2024
| Report Details |
| 200 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 200 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 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.
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.
Process Overview
Product
BPA. 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 Materials
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.
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Production Process Information
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Production Process Information
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Production Costs Datasheet
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Operating Cost Details
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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 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
Other Bisphenol A Production Cost Reports
BPA from Acetone and Phenol (Hydrogen Chloride Catalyst)
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.
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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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