Report No. 38 EPOXYRESINS. June A private report by the PROCESS ECONOMICS PROGRAM STANFORD RESEARCH INSTITUTE MENLO PARK, CALIFORNIA

Transcription

1 Report No. 38 EPOXYRESINS by ROBERT G. MULLER June 1968 A private report by the PROCESS ECONOMICS PROGRAM STANFORD RESEARCH INSTITUTE MENLO PARK, CALIFORNIA

2 CONTENTS 1 INTRODUCTION SUMMARY INDUSTRY STATUS COMMERCIAL EPOXY RESINS... DGEBA Resins... Phenoxy Resins... Novolac Resins... Flame-Resistant Resins... Cycloaliphatic Epoxy Resins... Flexible Epoxy Resins.... Miscellaneous Epoxy Resins... 5 CHARACTERIZATION OF EPOXY RESINS... Uncured Epoxy Resins... Factors Affecting Properties of Uncured Resins... Factors Affecting Properties of Cured Resins... Potential Improvements in Epoxy Resins... 6 DIGLYCIDYL ETHERS OF BISPHENOL A... Introduction... Chemistry... Part I Low-Molecular-Weight DGEBA Resins... Review of Processes... Process Description--Batch Process... Materials of Construction--Batch Process... Process Discussion--Batch Process.... Cost Estimates--Batch Process.... Capital Costs.... Production Costs... Process Description--Continuous Process... Process Discussion--Continuous Process... Cost Estimates--Continuous Process... Capital Costs.... Production Costs iii

3 CONTENTS 6 (continued) Part II Solid DGERA Resins Review of Processes Process Description Process Discussion Cost Estimates Capital Costs Production Costs Part III High-Molecular-Weight DGERA Resins Review of Processes Process Description Process Discussion Cost Estimates Capital Cost Production Costs Cost Integration EPOXY NOVOLAC RESINS... Chemistry... Review of Processes... Process Description... Materials of Construction... Process Discussion... Cost Estimates... Capital Costs... Production Costs OTHER GLYCIDYL-TYPE EPOXY RESINS Glycidyl Ethers of Phenols Glycidyl Ethers of Aliphatic Polyols' Miscellaneous Glycidyl Resins Epoxy Resins from Monoepoxides CYCLOALIPHATIC EPOXY RESINS Chemistry and Processes Epoxidation Reaction Peracetic Acid Preparation Olefin Raw Materials Commercial Production iv

4 CONTENTS 10 EPOXY FORMULATIONS... Curing Agents... Accelerators... Diluents... Fillers... Other Additives and Modifiers... Formulations in General APPENDIX A DESIGN AND COST BASIS APPENDIX B PHYSICAL DATA APPENDIX c RAW MATERIAL SPECIFICATIONS APPENDIX D SAFETY AND TOXICITY CITED REFERENCES V

5 ILLUSTRATIONS 3.1 Production and Sales of Unmodified Epoxy Resins in the United States ,, Effect of Operating Rate and Production Level on Batch Process for DGEBA Resins , Low-Molecular-Weight DGEBA Resins by Continuous Process. 6.4 Effect of Operating Rate and Production Level on Continuous Process for DGEBA Resins Solid DGEBA Resins by Batch Process Effect of Operating Rate and Production Level on Batch Process for Solid DGRBA Resins High-Molecular-Weight DGEBA Resins Epoxy Novolac Resins.., Effect of Operating Rate and Production Level on Cost of Epoxy Novolac Resins vii

6 TABLES 2.1 Summary of Costs for Evaluated Processes Plant Capacity Americas Plant Capacity Europe, Africa, Asia, and Australia Consumption of Unmodified Epoxy Resins in the United States Properties of Typical Commercial Resins Commercial Cycloaliphatic Epoxy Resins Commercial Flexible Resins Theoretical Configuration of DGEBA Resins DGEBA Resins Summary of Processes Major Process Equipment and Utilities Summary StreamFlows... Process Unit and Utilities Investment Total Capital Investment Production Costs Low-Molecular-Weight DGEBA Resins by Continuous Process Major Process Equipment and Utilities Summary IX

7 TABLE6 6.9 Low-Molecular-Weight DGEBA Resins by Continuous Process Stream Flows Low-Molecular-Weight DGEBA Resins by Continuous Process Process Unit and Utilities Investment Low-Molecular-Weight DGEBA Resins by Continuous Process Total Capital Investment Low-Molecular-Weight BGEBA Resins by Continuous Process Production Costs Solid DGEBA Resins by Batch Process Major Process Equipment and Utilities Summary Solid BGEBA Resins by Batch Process StreamFlows W Solid BGEBA Resins by Batch Process Process Unit and Utilities Investment Solid DGEBA Resins by Batch Process Total Capital Investment Solid DGEBA Resins by Batch Process Production Costs High-Molecular-Weight DGEBA Resins Major Process Equipment and Utilities Summary High-Molecular-Weight BGEBA Resins StreamFlows High-Molecular-Weight BGEBA Resins Process Unit and Utilities Investment High-Molecular-Weight BGEBA Resins Total Capital Investment High-Molecular-Weight BGEBA Resins Production Costs X

8 TABLES 7.1 Theoretical Configuration of Epoxy Novolac Resins Effect of Phenol-Formaldehyde Ratio on Molecular Weight ofnovolac Epoxy Novolac Resins Major Process Equipment and Utilities Summary Epoxy Novolac Resins StreamFlows Epoxy Novolac Resins Process Unit and Utilities Investment Epoxy Novolac Resins Total Capital Investment Epoxy Novolac Resins Production Costs Xi