Expandable Polystyrene Production
Polystyrene Production Costs Report | Issue C | Q4 2024
| Report Details |
| 150 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 150 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 study presents the economics of Expandable Polystyrene (EPS) production from styrene in the United States, via a typical batch suspension polymerization process. The tiny spheres of EPS are impregnated with a physical blowing agent.
The report provides a comprehensive study of Polystyrene production and related Polystyrene production cost, covering three key aspects: a complete description of the Polystyrene production process examined; an in-depth analysis of the related Polystyrene plant capital cost (Capex); and an evaluation of the respective Polystyrene plant operating costs (Opex).
The Polystyrene 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 Polystyrene 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 Polystyrene 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 two major sections: (1) Polymerization; and (2) Polymer separation and finishing.
Polymerization. Styrene monomer feed stream, demineralized water, polymerization initiators, blowing agent, suspending agents and additives are supplied to a stirred reactor. The reaction occurs substantially in the liquid phase, in styrene droplets dispersed in water, used as diluent. After polymerization ignition, the heat from the exothermic reaction is removed by means of cooling water. The polymerization occurs according to a time-temperature profile, under agitation. As the polymer is formed, it precipitates out of the reaction medium, floating in the liquid monomer phase as polymer beads. The polymerization is interrupted when the conversion of styrene to Polystyrene reaches 100% and the polymer slurry is fed to a hold tank.
Polymer separation and finishing. The polymer slurry is then passed through a centrifuge, in such a way that Polystyrene beads containing only residual moisture are obtained. At this point, the Polystyrene beads are conveyed to a drying step. The Polystyrene beads obtained are screened, coated, packed and sent to storage facilities.
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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 Polystyrene 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 Polystyrene 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 Polystyrene 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 Polystyrene 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 Polystyrene Production Cost Reports
General Purpose Polystyrene Production
This report presents the economics of General Purpose Polystyrene (GPPS) production from styrene in the United States, via a typical continuous bulk polymerization process, split into a pre-polymerization and a polymerization step. Both steps are conducted in continuous stirred-tank reactors.
Details: 180 kta United States-based plant | Q4 2024 | 107 pages | Issue A From $799 USD
The cost analyses presented in this report target a 180 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.
High Impact Polystyrene Production
This study presents the economics of High Impact Polystyrene (HIPS) production from styrene in the United States, via a typical continuous bulk polymerization process, which occurs in the presence of polybutadiene. The process is split into a pre-polymerization and a polymerization step. The first step is conducted in CSTRs and the second in plug-flow reactors.
Details: 180 kta United States-based plant | Q4 2024 | 107 pages | Issue B From $799 USD
The cost analyses presented in this report target a 180 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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