PEP Report 50E POLYCARBONATE By Susan Bell (October 2007)

Transcription

1 PEP Report 50E POLYCARBONATE By Susan Bell (October 2007) ABSTRACT This report continues our review of polycarbonate production technology, supplementing our earlier report PEP Report 50D issued in Polycarbonate resins are commercially produced by interfacial and transesterification or melt processes. In the interfacial process, bisphenol A (BPA) is phosgenated in an aqueous solution of sodium bisphenolate with methylene chloride as an organic solvent. In the melt process, BPA reacts with diphenyl carbonate (DPC) in a molten state without the solvent. In this report, we update the process economics and technology to produce DPC by: DPC from phenol by direct phosgenation DPC from ester exchange reaction of DMC, which is produced by the oxidative carbonylation of methanol DPC from ester exchange reaction of DMC, which is produced by reacting ethylene oxide with CO 2 to form ethylene carbonate. Ethylene carbonate is reacted with methanol to produce DMC. DPC from liquid-phase decarbonylation of DPO, which is produced by reacting phenol with DMO. DMO is prepared by the carbonylation of methyl nitrite. In this report, we also update the process economics and technology to produce polycarbonate by several processes: Polycarbonate by the interfacial process with on-site phosgene generation Polycarbonate by a conventional melt process with DPC and BPA as the starting materials Polycarbonate by a melt process similar to Asahi Kasei process with DPC and BPA as the starting materials SRI Consulting PEP Report 50E

2 R eport No. 50E P OL Y C A R B ONA T E by S US A N B E L L Oc tober 2007 A private report by the P R OC E S S E C ONOMIC S P R OG R A M SR I Menlo P ark, C alifornia 94025

3 SRIC agrees to assign professionally qualified personnel to the preparation of the Process Economics Program s reports and will perform the work in conformance with generally accepted professional standards. No other warranties expressed or implied are made. Because the reports are of an advisory nature, neither SRIC nor its employees will assume any liability for the special or consequential damages arising from the Client s use of the results contained in the reports. The Client agrees to indemnify, defend, and hold SRIC, its officers, and employees harmless from any liability to any third party resulting directly or indirectly from the Client s use of the reports or other deliverables produced by SRIC pursuant to this agreement For detailed marketing data and information, the reader is referred to one of the SRI Consulting programs specializing in marketing research. THE CHEMICAL ECONOMICS HANDBOOK Program covers most major chemicals and chemical products produced in the United States and the WORLD PETROCHEMICALS PROGRAM covers major hydrocarbons and their derivatives on a worldwide basis. In addition the SRIC DIRECTORY OF CHEMICAL PRODUCERS services provide detailed lists of chemical producers by company, product, and plant for the United States, Western Europe, Canada, and East Asia, South America and Mexico.

4 CONTENTS GLOSSARY... xii 1 INTRODUCTION SUMMARY INDUSTRY STATUS TECHNICAL ASPECTS ECONOMICS Diphenyl Carbonate Production Polycarbonate Production INDUSTRY STATUS INTRODUCTION APPLICATIONS/END USES CAPACITY AND DEMAND PRODUCERS POLYCARBONATE TECHNOLOGY INTRODUCTION POLYCARBONATE PRODUCTION BY THE INTERFACIAL PROCESS POLYCARBONATE PRODUCTION BY THE MELT PROCESS DIPHENYLCARBONATE PRODUCTION Conventional DPC Production using Phosgene DPC Production by Non-Phosgenation Processes DPC Production from Dimethyl Carbonate (DMC) by Ester Exchange with Phenol or Phenyl Acetate DMC Production DMC Production from Oxidative Carbonylation of Methanol DMC Production from Oxirane DPC Production from Phenol via Diphenyl Oxalate (DPO) SRI Consulting iii PEP Report 50E

5 CONTENTS (Continued) DPC Production from Phenol by Direct Oxidative Carbonylation POLYCARBONATE PRODUCTION BY AN INTERFACIAL PROCESS INTRODUCTION POLYCARBONATE PRODUCTION BY AN INTERFACIAL PROCESS Process Description Section 100: Raw Material Storage and Mixing Section 200: Polymerization and Purification Section 300: Polymer and Solvent Recovery Section 400: Compounding and Bulk Handling COST ESTIMATES Total Fixed Capital Production Costs DIPHENYL CARBONATE PRODUCTION INTRODUCTION DIPHENYL CARBONATE PRODUCTION BY A PHOSGENE PROCESS Process Description COST ESTIMATES Total Fixed Capital Production Costs DIPHENYL CARBONATE PRODUCTION BY NON-PHOSGENE PROCESSES Diphenyl Carbonate Production by a Process Similar to Asahi Kasei Process Process Description Section 100: Ethylene Carbonate Production Section 200: Dimethyl Carbonate Production Section 300: Diphenyl Carbonate Production Process Discussion Ethylene Carbonate Production SRI Consulting iv PEP Report 50E

6 CONTENTS (Continued) Dimethyl Carbonate Production Diphenyl Carbonate Production COST ESTIMATES Total Fixed Capital Production Costs Diphenyl Carbonate Production by a Process Similar to Ube Process Process Description Section 100: Dimethyl Oxalate Production Section 200: Diphenyl Oxalate Production Section 300: Diphenyl Carbonate Production Process Discussion COST ESTIMATES Total Fixed Capital Production Costs Diphenyl Carbonate Production by a Process Similar to GE Process Process Description Section 100: Dimethyl Carbonate Production Section 200: Diphenyl Carbonate Production Process Discussion COST ESTIMATES Total Fixed Capital Production Costs POLYCARBONATE PRODUCTION BY A MELT PROCESS INTRODUCTION POLYCARBONATE PRODUCTION BY A CONVENTIONAL MELT PROCESS Process Description COST ESTIMATES Total Fixed Capital SRI Consulting v PEP Report 50E

7 CONTENTS (Concluded) Production Costs POLYCARBONATE PRODUCTION BY A MELT PROCESS SIMILAR TO ASAHI KASEI S PROCESS Process Description COST ESTIMATES Total Fixed Capital Production Costs 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 SRI Consulting vi PEP Report 50E

8 FIGURES 2.1 DPC Price Variation with EO Price (Asahi Kasei Process) DPC Price Variation with EG Price (Asahi Kasei Process) Asahi Kasei s Guide-Wetting Fall Type Polymerizer Different Routes to Produce DPC Different Routes to Produce DMC Polycarbonate Production by an Interfacial Process... E Diphenyl Carbonate Production by a Phosgene Process... E Diphenyl Carbonate Production by a Process Similar to Asahi Kasei Process... E Diphenyl Carbonate Production by a Process Similar to Ube Process... E Diphenyl Carbonate Production by a Process Similar to GE Process... E Polycarbonate Production by a Conventional Melt Process... E Polycarbonate Product Values Based on DPC and BPA Unit Costs Polycarbonate Production by a Melt Process Similar to Asahi Kasei Process... E-27 SRI Consulting vii PEP Report 50E

9 TABLES 2.1 Leading Global Producers of Polycarbonate Resin, Capital Cost Comparison of DPC Production Processes Production Cost Comparison of DPC Production Processes Capital Cost Comparison of Polycarbonate Production Processes Production Cost Comparison of Polycarbonate Production Processes Consumption of Polycarbonate Resins by Major Region and End Use Polycarbonate Demand Growth Rate by Major Regions Polycarbonate Supply and Demand by Major Regions Leading Global Producers of Polycarbonate Resin, Polycarbonate Producers (2006) Polycarbonate Production by the Interfacial Process... A Diphenyl Carbonate Production... A Polycarbonate Production by the Melt Process... A Polycarbonate Production by Solid State Polymerization... A Polycarbonate Production by an Interfacial Process with On-Site Phosgene Generation: DESIGN BASES AND ASSUMPTIONS Polycarbonate Production by an Interfacial Process with On-Site Phosgene Generation: STREAM FLOWS Polycarbonate Production by an Interfacial Process with On-Site Phosgene Generation: MAJOR EQUIPMENT Polycarbonate Production by an Interfacial Process with On-Site Phosgene Generation: UTILITIES SUMMARY Polycarbonate Production by an Interfacial Process with On-Site Phosgene Generation: TOTAL CAPITAL INVESTMENT Polycarbonate Production by an Interfacial Process with On-Site Phosgene Generation: CAPITAL INVESTMENT BY SECTION Polycarbonate Production by an Interfacial Process with On-Site Phosgene Generation: PRODUCTION COSTS Diphenyl Carbonate Production by a Phosgene Process: DESIGN BASES AND ASSUMPTIONS SRI Consulting viii PEP Report 50E

10 TABLES (Continued) 6.2 Diphenyl Carbonate Production by a Phosgene Process: STREAM FLOWS Polycarbonate Production by an Interfacial Process with On-Site Phosgene Generation: MAJOR EQUIPMENT Diphenyl Carbonate Production by a Phosgene Process: UTILITIES SUMMARY Diphenyl Carbonate Production by a Phosgene Process: TOTAL CAPITAL INVESTMENT Diphenyl Carbonate Production by a Phosgene Process: PRODUCTION COSTS Diphenyl Carbonate Production by a Process Similar to Asahi Kasei Process: DESIGN BASES AND ASSUMPTIONS Diphenyl Carbonate Production by a Process Similar to Asahi Kasei Process: STREAM FLOWS Diphenyl Carbonate Production by a Process Similar to Asahi Kasei Process: MAJOR EQUIPMENT Diphenyl Carbonate Production by a Process Similar to Asahi Kasei Process: UTILITIES SUMMARY Diphenyl Carbonate Production by a Process Similar to Asahi Kasei Process: TOTAL CAPITAL INVESTMENT Diphenyl Carbonate Production by a Process Similar to Asahi Kasei Process: CAPITAL INVESTMENT BY SECTION Diphenyl Carbonate Production by a Process Similar to Asahi Kasei Process: PRODUCTION COSTS Historical Ethylene Glycol Prices Based on U.S. Gulf Coast Diphenyl Carbonate Production by a Process Similar to Ube Process: DESIGN BASES AND ASSUMPTIONS Diphenyl Carbonate Production by a Process Similar to Ube Process: STREAM FLOWS Diphenyl Carbonate Production by a Process Similar to Ube Process: MAJOR EQUIPMENT Diphenyl Carbonate Production by a Process Similar to Ube Process: UTILITIES SUMMARY Diphenyl Carbonate Production by a Process Similar to Ube Process: TOTAL CAPITAL INVESTMENT SRI Consulting ix PEP Report 50E

11 TABLES (Continued) 6.20 Diphenyl Carbonate Production by a Process Similar to Ube Process: CAPITAL INVESTMENT BY SECTION Diphenyl Carbonate Production by a Process Similar to Ube Process: PRODUCTION COSTS Diphenyl Carbonate Production by a Process Similar to GE Process: DESIGN BASES AND ASSUMPTIONS Diphenyl Carbonate Production by a Process Similar to GE Process: STREAM FLOWS Diphenyl Carbonate Production by a Process Similar to GE Process: MAJOR EQUIPMENT Diphenyl Carbonate Production by a Process Similar to GE Process: UTILITIES SUMMARY Diphenyl Carbonate Production by a Process Similar to GE Process: TOTAL CAPITAL INVESTMENT Diphenyl Carbonate Production by a Process Similar to GE Process: CAPITAL INVESTMENT BY SECTION Diphenyl Carbonate Production by a Process Similar to GE Process: PRODUCTION COSTS Polycarbonate Production by a Conventional Melt Process: DESIGN BASES AND ASSUMPTIONS Polycarbonate Production by a Conventional Melt Process: STREAM FLOWS Polycarbonate Production by a Conventional Melt Process: UTILITIES SUMMARY Polycarbonate Production by a Conventional Melt Process: TOTAL CAPITAL INVESTMENT Polycarbonate Production by a Conventional Melt Process: CAPITAL INVESTMENT BY SECTION Polycarbonate Production by a Conventional Melt Process: PRODUCTION COSTS Unit Costs of DPC and BPA Polycarbonate Production by a Melt Process Similar to Asahi Kasei Process: DESIGN BASES AND ASSUMPTIONS Polycarbonate Production by a Melt Process Similar to Asahi Kasei Process: STREAM FLOWS SRI Consulting x PEP Report 50E

12 TABLES (Concluded) 7.10 Diphenyl Carbonate Production by a Process Similar to Ube Process: MAJOR EQUIPMENT Polycarbonate Production by a Melt Process Similar to Asahi Kasei Process: UTILITIES SUMMARY Polycarbonate Production by a Melt Process Similar to Asahi Kasei Process: TOTAL CAPITAL INVESTMENT Polycarbonate Production by a Melt Process Similar to Asahi Kasei Process: CAPITAL INVESTMENT BY SECTION Polycarbonate Production by a Melt Process Similar to Asahi Kasei Process: PRODUCTION COSTS SRI Consulting xi PEP Report 50E