High Viscosity Silicone Fluid Production
Silicone Production Costs Report | Issue B | Q3 2024
| Report Details |
| 12 kta United States-based plant | Q3 2024 | 107 pages |
This report presents a cost analysis of a 12 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 High Viscosity Silicone Fluid production in the United States. The assessment concerns a plant producing Polydimethylsiloxane (PDMS) by ring-opening polymerization starting from cyclic siloxanes (octamethylcyclotetrasiloxanes), using hexamethyldisiloxane for molecular weight control.
The report provides a comprehensive study of Silicone production and related Silicone production cost, covering three key aspects: a complete description of the Silicone production process examined; an in-depth analysis of the related Silicone plant capital cost (Capex); and an evaluation of the respective Silicone plant operating costs (Opex).
The Silicone 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 Silicone 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 Silicone 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 one major section: (1) Polymerization and (2) Evaporation.
Polymerization. The silicone production process initiates with the preparation of the polymerization catalyst, where octamethylcyclotetrasiloxane (D4) reacts with an aqueous solution of tetrabutylphosphonium hydroxide (TBPH), yielding tetrabutylphosphonium silanolate. This catalyst is employed in the subsequent polymerization step, where a blend of fresh D4, hexamethyldisiloxane (MM), and the formed catalyst undergoes polymerization within a heated tubular reactor, resulting in the formation of high viscosity Silicone. Following the reaction, a heat exchanger elevates the product's temperature to stabilize the Silicone oil while decomposing the catalyst into volatile components, readying the mixture for evaporation.
Evaporation. In the evaporation phase, a thin film evaporator removes volatile residues, including unreacted D4 and MM, from the Silicone stream, with the extracted gases being discarded. Ultimately, the purified Silicone product is stored in a surge tank at a controlled temperature, before being sent to storage.
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Production Process Information
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Production Process Information
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Operating Cost Summary
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 Silicone 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 Silicone 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 Silicone 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 Silicone 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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Details: 6 kta United States-based plant | Q3 2024 | 107 pages | Issue C From $1,999 USD
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