PROCESS ECONOMICS PROGRAM
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1 PROCESS ECONOMICS PROGRAM SRI INTERNATIONAL Menlo Park, California Abstract Process Economics Program Report No. 155 ETHYLENE COPOLYMERS (March 1983) This report covers the technology and costs of manufacturing three ethylene copolymers: ethylene-vinyl acetate, ethylene-methacrylic acid ionomer, and ethylene-methyl acrylate. Ethylene-vinyl acetate copolymer is produced by a high pressure process similar to that used In the msnufacture of LDPB. A design using a tubular reactor system is presented. Ethylene-methacrylic acid ionomer is produced by reacting ethylene and methacrylic acid in a high pressure autoclave. The resulting copolymer Is contacted with either sodium or zinc salts to form the iouomer. Ethylene-methyl acrylate copolymer is produced by a high pressure autoclave process. Also presented 1s a review of the literature concerning ethylene- carbon monoxide copolymers. PEP 81 MA/MIS
2 Report No. 155 ETHYLENE COPOLYMERS by MICHAEL ARNE ROBERT H. SCHWAAR March 1983 A private report by the PROCESS ECONOMICS PROGRAM Menlo Park, California 94025
3 For detailed marketing data and information, the reader is referred to one of the SRI programs specializing research. in marketing The CHRMICAL ECONOMICS HANDBOOK Program covers most major chemicals and chemical products produced in the United States and the WORLD PETROCHRMICALS Program covers major hydrocarbons and their derivatives.on a worldwide basis. In addition, the SRI DIRECTORY OF CHEMICAL PRODUCERS services provide detailed lists of chemical producers by company, prod- uct, and plant for the United States and Western Europe. ii
4 CONTENTS 1 INTRODUCTION SUMMARY... 3 Ethylene-Vinyl Acetate Ethylene-Methyl Acrylate... 7 Ethylene-Carbon Monoxide INDUSTRY STATUS Ethylene-Vinyl Acetate Ethylene-Methyl Acrylate Ethylene-Acrylic Acid Ethylene-Ethyl Acrylate ETRTLENR-VINYL ACETATE COPOLYMERS.. 15 Chemistry...' Process Review 16 Process Description Polymerization and Recovery Finishing. 23 Process Discussion Polymerization and Recovery Finishing... ; Materials of Construction Feed Specifications Waste Streams Cost Estimates 31 Capital Costs Production Costs ETRYLENE-METHACRYLIC ACID IONOMERS Chemistry.. 41 Process Review 43 Process Description Polymerization and Recovery...., Naturalization and Finishing Process Discussion Polymerization and Recovery iii
5 CONTENTS 5 ETHYLENE-METHACRYLIC ACID IONOMERS (Continued) Neutralization and Finishing Materials of Construction Feed Specifications Waste Streams... :i Cost Estimates Capital Costs Production Costs ETHYLENE-METHYL ACRYLATE COPOLYMERS. 65 Chemistry.. ;6' Process Review.... Process Description Polymerizatien and Recovery Finishing. 3: Process Discussion... Polymerization and Recovery Finishing. :: Materials of Construction... Feed Specifications Waste Streams Cost Estimates.... ;i Capital Costs... Production Costs ETHYLENE-CARBON MONOXIDE COPOLYMERS. 89 Chemistry.. 89 Process Review Conclusions. 94 APPENDIX A PHYSICAL PROPERTIES OF ETHYLENE COPOLYMERS CITED REFERENCES PATENT REFERENCES BY COMPANY..., IV
6 ILLUSTRATIONS Flow Sheet...:., Product Value as a Function of Vinyl Acetate Content.,.. Effect of,operating Level and Plant Capacity on Product Value Flow Sheet. Effect of Operating Level and Plant Capacity on Product Value Ethylene-Methyl Acrylate Copolymer Flow Sheet. Ethylene-Methyl Acrylate Copolymer Product Value as a Function of Ethylene Feedstock Price.. Ethylene-Methyl Acrylate Copolymer Effect of Operating Level and Plant Capacity 0n Product Value V
7 TABLES Summary of Ethylene Copolymer Economics... U.S. Manufacturers of Ethylene Copolymers... Japanese Manufacturers of Ethylene Copolymers... Patent Sunmary... Design Bases... Stream Flows... Major Equipment.... Capital Investment... Major Equipment Costs... Production Costs... Patent Summary... Design Bases... Ethylene-Methacrylic Acid Copolymer Ionomer Stream Flows... Major Equipment... Capital Investment... Major Equipment Costs... Production Costs... Ethylene-Methyl Acrylate Copolymer Patent Summary Vii
8 TABLES 6.2. Ethylene-Methyl Acrylate Copolymer Copolymerization Reaction Data Ethylene-Methyl Acrylate Copolymer Design Bases Ethylene-Methyl Acrylate Copolymer Stream Flows Ethyleqe-Methyl Acrylate Copolymer Major Equipment Ethylene-Methyl Acrylate Copolymer Capital Investment Ethylene-Methyl Acrylate Copolymer Major Equipment Costs ,8 Ethylene-Methyl Acrylate Copolymer Production Costs Ethylene-Carbon Monoxide Copolymer Patent Summary.... i % Viii
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