Abstract Process Economics Program Report 244 STRATEGIC BUSINESS UNITS OF EPOXY AND POLYCARBONATE RESINS (June 2002)

Transcription

1 Abstract Process Economics Program Report 244 STRATEGIC BUSINESS UNITS OF EPOXY AND POLYCARBONATE RESINS (June 2002) This report presents economics for three of strategic business units (SBUs) for the production of polycarbonate and epoxy resins. The SBU is an integrated operation, which combines the production of the resin with the production of its respective precursor(s). The determination of the configuration of each SBU is based on the information of worldwide production capacities for the resins and their precursors. The latter includes bisphenol A (BPA) and diphenyl carbonate (DPC) for polycarbonate, and epichlorohydrin (ECH) and BPA for epoxy resins. This report also presents review of technology and economics of the processes for the production of these precursors and the resins as listed below. The processes for precursors ECH from propylene by chlorination and dehydrochlorination. BPA from phenol and acetone by improved cation exchange resin process DPC from phenol and DMC, which is prepared by oxidative carbonylation, by reactive distillation DPC from phenol by direct phosgenation DPC from phenol by oxidative carbonylation. The processes for the resins Polycarbonate by interfacial process with on-site production of phosgene Polycarbonate by integrated melt process with DPC prepared from phenol and DMC, which is prepared by oxidative carbonylation of methanol Polycarbonate by integrated melt process with DPC prepared by direct phosgenation Polycarbonate by integrated melt process with DPC prepared by oxidative carbonylation Diglycidyl ether of bisphenol A (DGEBA) from BPA and ECH Solid Epoxy Resin from DGEBA and BPA by advancement process High molecular weight (MW) epoxy solution from DGEBA and BPA in MEK solvent. The demand for polycarbonate in 2001 is estimated at 1.8 million metric tons of which 40% is accounted for by Asian consumption, more than 30% by the consumption of North America, and 22% by the consumption of Western Europe. The demand for epoxy resins in 2001 is estimated at 1.2 million metric tons, of which 48% is accounted for by Asian consumption, more PEP 01 YRC

2 CONTENTS 1 INTRODUCTION SUMMARY TECHNICAL ASPECTS Precursors for Polycarbonate and Epoxy Resins Improved Cation Exchange Resin Process for BPA DPC from Phenol by the Direct Phosgenation Process DPC from Phenol via DMC by Oxidative Caronylation of Methanol DPC from Phenol by the Oxidative Carbonylation Process Epichlorohydrin from Propylene and chlorine via Allyl Chloride Preparation of Polycarbonate and Epoxy Resins Polycarbonate by Interfacial Process Polycarbonate by Melt Process Liquid Epoxy Resin from BPA and ECH by continuous Process Solid Epoxy Resin from DGEBA and BPA by Advancement Process High MW Epoxy Solution from DGEBA and BPA in MEK Strategic Business Units for Polycarbonate and Epoxy Resins SUMMARY OF ECONOMICS Economics for Polycarbonate and its precursors Economics for Epoxy Resin and its precursors Economics for Polycarbonate and Epoxy SBUs INDUSTRY STATUS INTRODUCTION CONSUMPTION OF POLYCARBONATE AND EPOXY RESINS PRODUCTION CAPACITY Producers of Bisphenol A Producers of Epichlorohydrin Producers of Epoxy Resins iii

3 CONTENTS (Continued) Producers of Polycarbonate REVIEW OF TECHNOLOGY FOR EPOXY AND POLYCARBONATE RESINS REVIEW OF TECHNOLOGY FOR PRECURSORS OF EPOXY AND POLYCARBONATE Technology for Epichlorohydrin Preparation of Bispenol A Preparation of Diphenyl Carbonate REVIEW OF TECHNOLOGY FOR EPOXY RESINS REVIEW OF TECHNOLOGY FOR POLYCARBONATE RESINS Polycarbonate by Interfacial Process Modified Polycarbonates Polycarbonate by Transesterification (Melt) Process Solid State Polycondensation ECONOMICS FOR POLYCARBONATE AND ITS PRECURSORS INTRODUCTION COMMERCIAL PROCESSES FOR THE PRODUCTION OF BISPHENOL A BPA from Phenol and Acetone by the Improved Process Process Description Cost Estimates POTENTIAL PROCESSES FOR THE PRODUCTION OF DPC DPC from Phenol by the Direct Phosgenation Process Process Description Cost Estimates DPC from Phenol via DMC by Oxidative Carbonylation of Methanol Process Description Cost Estimates DPC from Phenol by the Oxidative Carbonylation Process Cost Estimates iv

4 CONTENTS (Continued) COMMERCIAL PROCESSES FOR POLYCARBONATE RESINS POLYCARBONATE BY THE INTERFACIAL PROCESS Process Description Cost Estimates POLYCARBONATE FROM BPA AND DPC BY THE MELT PROCESS Process Description Economics ECONOMICS FOR EPOXY RESINS AND THEIR PRECURSORS INTRODUCTION EPICHLOROHYDRIN FROM PROPYLENE AND CHLORINE VIA ALLYL CHLORIDE Process Description Economics PRODUCTION OF EPOXY RESINS LIQUID EPOXY RESIN FROM BPA AND ECH BY CONTINUOUS PROCESS Process Description Economics SOLID EPOXY RESIN FROM DGEBA AND BPA BY ADVANCEMENT PROCESS 6-14 Process Description Economics HIGH MW EPOXY SOLUTION FROM DGEBA AND BPA IN METHYL ETHYL KETONE Process Description Economics ECONOMICS FOR STRATEGIC BUSINESS UNITS FOR EPOXY AND POLYCARBONATE RESINS INTRODUCTION v

5 STRATEGIC UNITS FOR THE PRODUCTION OF POLYCARBONATE RESINS CONTENTS (Concluded) PC-SBU1 Description PC-SBU1 Cost Estimates PC-SBU2A Description PC-SBU2A Cost Estimates PC-SBU2B Description PC-SBU2B Cost Estimates PC-SBU2C Description PC-SBU2C Cost Estimates STRATEGIC UNITS FOR THE PRODUCTION OF EPOXY RESINS EP-SBU1 Description EP-SBU1A Cost Estimates EP-SBU1B Cost Estimates EP-SBU1C Cost Estimates EP-SBU1D Cost Estimates ECONOMICS COMPARISON OF SBUS FOR POLYCARBONATE AND EPOXY RESINS APPENDIX A: PATENT SUMMARY TABLES... A-1 APPENDIX B: DESIGN AND COST BASES... B-1 APPENDIX C: CITED REFERENCES... C-1 APPENDIX D: PATENT REFERENCES BY COMPANY... D-1 APPENDIX E: PROCESS FLOW DIAGRAM... E-1 vi

6 ILLUSTRATIONS 5.1 BPA from Phenol and Acetone by Improved Process Process Flow Diagram... E DPC from Phenol by Direct Phosgenation Process Process Flow Diagram... E DPC from Phenol via DMC by Oxidative Carbonylation of Methanol Process Flow Diagram... E DPC from Phenol by Oxidative Carbonylation Process Process Flow Diagram... E Polycarbonate by Interfacial Process Process Flow Diagram... E Polycarbonate by Conventional Melt Process Process Flow Diagram... E Epichlorohydrin from Propylene via Allyl Chloride by Chlorination Process Flow Diagram... E Diglycidyl Ether of Bisphenol A by Continuous Process Process Flow Diagram... E Solid Epoxy Resin from BDEBA and Bisphenol A Process Flow Diagram... E High MW Epoxy Resin Solution from DGEBA and Bisphenol A Process Flow Diagram... E-29 vii

7 TABLES 2.1 Economics for Bisphenol A and Diphenyl Carbonate Economic Summary Economics for Polycarbonate by Interfacial and Melt Processes Economic Summary Economic for ECH and Epoxy Resins Economic Summary Economics of SBUs for Polycarbonate Resins Economic Comparison Economics of SBUs for Epoxy Resins Economic Comparison Distribution of Polycarbonate Resins Consumption in the Major Consumption Regions Distribution of Epoxy Resins Consumption in Major Consumption Regions World Bisphenol A Producers World Epichlorohydrin Producers Production Capacity World Three Large Producers for Epichlorohydrin Production Capacity World Epoxy Resins Producers Production Capacity World Largest Producers for Epoxy Resins Production Capacity Producers of Polycarbonate Worldwide Production Capacity World Five Largest Producers for Polycarbonate Production Capacity Bisphenol A by Improved Cation Exchange Resin Technology Utilities Summary Bisphenol A by Improved Cation Exchange Resin Technology Major Equipment Bisphenol A by Improved Cation Exchange Resin Technology Total Capital Investment Bisphenol A by Improved Cation Exchange Resin Technology Capital Investment by Section viii

8 TABLES (Continued) 5.5 Bisphenol A by Improved Cation Exchange Resin Technology Production Costs Diphenyl Carbonate from Phenol by Direct Phosgenation Utilities Summary Diphenyl Carbonate from Phenol by Direct Phosgenation Major Equipment Diphenyl Carbonate from Phenol by Direct Phosgenation Total Capital Investment Diphenyl Carbonate from Phenol by Direct Phosgenation Production Costs Diphenyl Carbonate from Phenol via DMC by Oxidative Carbonylation and Reactive Distillation Utilities Summary Diphenyl Carbonate from Phenol via DMC by Oxidative Carbonylation and Reactive Distillation Major Equipment Diphenyl Carbonate from Phenol via DMC by Oxidative Carbonylation and Reactive Distillation Total Capital Investment Diphenyl Carbonate from Phenol via DMC by Oxidative Carbonylation and Reactive Distillation Capital Investment by Section Diphenyl Carbonate from Phenol via DMC by Oxidative Carbonylation and Reactive Distillation Production Costs Diphenyl Carbonate from Phenol by Oxidative Carbonylation with Fixed-Bed Reactors Utilities Summary Diphenyl Carbonate from Phenol by Oxidative Carbonylation with Fixed-Bed Reactors Major Equipment Diphenyl Carbonate from Phenol by Oxidative Carbonylation with Fixed-Bed Reactors Total Capital Investment Diphenyl Carbonate from Phenol by Oxidative Carbonylation with Fixed-Bed Reactors Production Costs ix

9 TABLES (Continued) 5.20 Polycarbonate by Interfacial Process with On-Site Phosgene Generation Utilities Summary Polycarbonate by Interfacial Process with On-Site Phosgene Generation Major Equipment Polycarbonate by Interfacial Process with On-Site Phosgene Generation Total Capital Investment Polycarbonate by Interfacial Process with On-Site Phosgene Generation Capital Investment by Section Epichlorohydrin from Propylene Via Allyl Chloride by Chlorination Utilities Summar Epichlorohydrin from Propylene Via Allyl Chloride by Chlorination Total Capital Investment Epichlorohydrin from Propylene Via Allyl Chloride by Chlorination Production Costs LER from BPA and ECH A by Continuous Process Utilities Summary LER from BPA and ECH A by Continuous Process Major Equipment LER from BPA and ECH A by Continuous Process Total Capital Investment LER from BPA and ECH A by Continuous Process Capital Investment by Section LER from BPA and ECH A by Continuous Process Production Costs Solid Epoxy Resin from DGEBA and Bisphenol A Utilities Summary Solid Epoxy Resin from DGEBA and Bisphenol A Major Equipment Solid Epoxy Resin from DGEBA and Bisphenol A Total Capital Investment Solid Epoxy Resin from DGEBA and Bisphenol A Production Costs High MW Epoxy Resin Solution from DGEBA and Bisphenol A Utilities Summary x

10 TABLES (Continued) 6.14 High MW Epoxy Resin Solution from DGEBA and Bisphenol A Major Equipment High MW Epoxy Resin Solution from DGEBA and Bisphenol A Total Capital Investment High MW Epoxy Resin Solution from DGEBA and Bisphenol A Production Costs Polycarbonate by Interfacial Process With On-Site Phosgene Generation Production Costs Polycarbonate by Interfacial Process With On-Site Phosgene Generation Production Costs (captive BPA) Polycarbonate by Non-Phosgene Melt Process Via DMC with Double- Tube Loop Reactors Production Costs Polycarbonate by Non-Phosgene Melt Process Via DMC with Double- Tube Loop Reactors Production Costs (captive BPA) Polycarbonate by Melt Process Via Diphenyl Carbonate by Direct Phosgenation Production Costs Polycarbonate by Melt Process Via Diphenyl Carbonate by Direct Phosgenation Production Costs (captive BPA) Polycarbonate by Nonphosgenation Melt Process Via Diphenyl Carbonate by Oxidative Carbonylation Production Costs Polycarbonate by Nonphosgenation Melt Process Via Diphenyl Carbonate by Oxidative Carbonylation Production Costs (captive BPA) Diglycidyl Ether of Bisphenol A by Continuous Process Production Costs Diglycidyl Ether of Bisphenol A by Continuous Process Production Costs (captive BPA and ECH Diglycidyl Ether of Bisphenol A by Continuous Process Production Costs Diglycidyl Ether of Bisphenol A by Continuous Process Production Costs (captive BPA and ECH) Solid Epoxy Resin from DGEBA and Bisphenol A Production Costs xi

11 TABLES (Concluded) 7.14 Solid Epoxy Resin from DGEBA and Bisphenol A Production Costs (captive BPA and DGEBA) High MW Epoxy Resin Solutions from DGEBA and Bisphenol A Production Costs High MW Epoxy Resin Solutions from DGEBA and Bisphenol A Production Costs (captive BPA and DGEBA Economics of SBUs for Polycarbonate Resins Economic Comparison Economics of SBUs for Epoxy Resins Economic Comparison xii

12 than 24% by the consumption of North America, and 23% by the consumption of Western Europe. PEP 01 YRC