PROCESS ECONOMICS PROGRAM

Transcription

1 Abstract Process Economics Program Report No. 207 SPECIALTY STYRENIC THERMOPLASTICS (October 1991) PROCESS ECONOMICS PROGRAM SRI INTERNATIONAL Menlo Park, California Specialty styrenic thermoplastics are styrene copolymers which have unique physical properties that make them useful in a variety of special applications. The styrenic portions of the polymer make these materials thermoplastics, allowing for good processibiiity when making automotive items, packaging, footwear, or other end-use products. in thls report, we review the manufacturing processes for making the four most significant specialty styrenic thermoplastics. We evaluate the technology and economics for making styrene-isoprene-styrene elastomers and styrene-butadiene resins by batch solution processes, styrene-maieic anhydride by a continuous solution process, and methacrylate-butadiene-styrene impact modifiers by a batch emulsion process. A valuable characteristic of specialty styrenic thermoplastics is their good processibility in conjunction with other properties such as elasticity, impact resistance, and heat resistance. In this report, we provide insights into the relationship between the important physical properties of styrenic thermoplastics and their molecular structure. We evaluate the status of this industry s specialty business niches and we also provide summaries of recent patents in the field. PEP 90 GMB

2 Report No. 207 SPECIALTY STYRENIC THERMOPLASTICS by GREGORY M. BOHLMANN I 1 E A private report by the October 1991 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 in marketing research. The CHEMCAL ECONOMCS HANDBOOK Program covers most major chemicals and chemical products produced in the United States and the WORLD PET/?OCHEMICALS Program covers major hydrocarbons and their derivatives on a worldwide basis. In addition, the SRI D/RECTORY OF C/-/EM/CAL PRODUCERS services provide detailed lists of chemical producers by company, product, and plant for the United States, Western Europe, Canada, and East Asia.

4 CONTENTS GLOSSARY XIII 1 INTRODUCTION l-l 2 SUMMARY... 2-l GENERAL ASPECTS... 2-l Btyrenic Block Copolymer Elastomers... 2-l Styrenic Block Copolymer Resins... 2-l Styrene-Maleic Anhydride Resin Methacrylate-Butadlene-StyTene TECHNICALASPECTS Styrenic Block Copolymer Elastomer Styrenic Block Copolymer Resin Styrene-Maieic Anhydride Resin Methacrylate-Butadiene-Styrene ECONOMICASPECTS INDUSTRY STATUS... 3-l OVERVIEW... 3-l STYRENIC BLOCK COPOLYMER ELASTOMERS... 3-l SIYRENIC BLOCK COPOLYMER RESINS SlYRENE-MALEIC ANHYDRIDE RESIN METHACRYLATE-BUTADIENE-STYRENE OTHER SPECIALTY STYRENICS RAWMATERIALS PROPERTIES OF SPECIALTY STYRENIC THERMOPLASTICS... 4-l SIYRENIC BLOCK COPOLYMER ELASTOMERS... 4-l SNRENIC BLOCK COPOLYMER RESINS SNRENE-MALEIC ANHYDRIDE RESIN MEIHACRYIATE-BUTADIENE-STYRENE iii -

5 5 STYRENIC BLOCK COPOLYMERS REVIEW OF PROCESSES... 5-l PROCESSDESCRlPTlON... FeedPuriflcation... Polylmization... Poiymer Recovery... soiventlwcovery... PROCESS DISCUSSION... Selection of Design Patents... Pfoduct~rades... ReactwLoadlng... 1,8-Bls(l-phenylethenylpenzene Availablllty... Product Pmty... waatetteatment... CAPlKM AND PRODUCTlON COSTS... DISCUSSION OF PRODUCT VALUE... 6 STYRENE-BUTADIENE RESIN... REVlEW OF PROCESSES... PROCESS DESCRlPllON... Feed Pulfication... Polymarization... PolymerRecovery... SolventRecovery... PROCESSDISCUSSION... SelectIon of Design Patents... Copoiymer Grades... Addithres... ProductPlMlty... FeedPurlflcatlon... copoiymef viscosity... WesteReatment... CAPITAL AND PRODUCTlON COSTS... DISCUSSKIN OF PRODUCT VALUE l 8-l

6 CONTENTS (Contkwecl) 7 STYRENE-MALEIC ANHYDRIDE RESIN... 7-l REVlEW OF PROCESSES l PROCESS DESCRlPTlON Polymerkatlon Polymer Recovery PROCESS DISCUSSION Selection of Deslgn Patents ProductGrades Polymer Vlscoslty ProductPurIty MaterialsofConstructlon CAPlTAL AND PRODUCTION COSTS DISCUSSION OF PRODUCT VALUE METHACRYLATE-BUTADIENE-STYRENE... 8-l REVlEW OF PROCESSES... 8-l PROCESS DESCRlPTlON Raw Material Preparatlon SB Emulslon Polymerization MBS Emulsion Polymerization PROCESS DISCUSSION Selection of Design Patents Emulsion Solids Content PartIcleSIze Product Purity CAPlTAL AND PRODUCTION COSTS DISCUSSION OF PRODUCT VALUE APPENDIX A: PATENT SUMMARY TABLES A-l APPENDIX B: DESIGN AND COST BASES B-l APPENDIX C: PHYSICAL PROPERTIES OF SPECIALTY STYRENIC THERMOPLASTICS C-l -V-

7 CONTENTS (Concluded) APPENDlX D: EQUIPMENT SUPPLIERS... D-l APPENDIX E: CITED REFERENCES... APPENDlX F: PATENT REFERENCES BY COMPANY... E-l F-l APPENDlX 0: PROCESS FLOW DIAGRAMS... G-l -vi -

8 ILLUSTRATIONS 4.1 POLYSTYRENE DOMAIN CONFIGURATIONS SBS BLOCK COPOLYMERS TENSILE STRENGTH VERSUS MONOMER RATlO STYRENIC BLOCK COPOLYMERS TENSILE STRENGTH VERSUS DIBLOCK CONTENT SlYRENlC BLOCK COPOLYMERS HARDNESS VERSUS MONOMER RATlO VlSCOSlTYlSHEAR RATE RElATlONSHlPS AT 200 C l SPIRAL FLOW AS A FUNCTlON OF MELT TEMPERATURE FOR IWO K-RESIN@ GRADES n AVERAGE RELATIONSHIP BElWEEN VICAT SOFTENING POINT, DEFLECTlON TEMPERATURE, AND GLASS-TRANSITION TEMPERATURE OF SMA HEAT RESISTANCE OF SMA VERSUS OTHER RESINS IMPACT STRENGTH OF SMA ENGINEERING RESINS AT VARIOUS SERVlCE TEMPERATURES SMA HIGH-SHEAR MELT VlSCOSllY VERSUS MOLECULAR WEIGHT SIS ELASTOMERS PROCESS FLOW DIAGRAM G SIS ElASTOMERS COMPARATlVE GEL PERMEATlON CHROMATOGRAPH SIS ELASTOMERS TENSILE STRENGTH VERSUS SIYRENE CONTENT SIS ELASTOMERS ULTlMATE ELONGATION VERSUS SlYRENE CONTENT STYRENE-BUTADIENE RESIN PROCESS FLOW DIAGRAM G SMRENE-BUTADIENE RESIN PRODUCT VALUE VERSUS SlYRENE PRICE STYRENE-MALEIC ANHYDRIDE RESIN PROCESS FLOW DIAGRAM G-15 -vii -

9 ILLUSTRATIONS (Concluded) 7.2 STYRENE-MALEIC ANHYDRIDE RESIN PRODUCT VALUE VERSUS SIYRENE PRICE , METHACRYLATE-BUTADIENE-SMRENE PROCESS FLOW DIAGRAM G METHACRYLATE-BUTADIENE-SlYRENE EFFECT OF OPERATING LEVEL AND PLANT CAPACITY ON PRODUCTlON COST l VIII -

10 TABLES 2.1 SPECIALTY STYRENIC THERMOPlASTlCS MANUFACTURING COST SUMMARY SPEClALlY SlYRENlC THERMOPLASTlCS 199OCONSUMPTlON l 3.2 PRODUCERS OF SlYRENlC BLOCK COPOLYMER ELASTOMERS PRODUCERS OF STYRENIC BLOCK COPOLYMER RESINS PRODUCERS OF SlYRENE-MALEIC ANHYDRIDE RESINS PRODUCERS OF METHACRYLATE-BUTADIENE-STYRENE STYRENIC BLOCK COPOLYMERS PATENT SUMMARY *...a... A SIS ELASTOMERS DESIGN BASES AND ASSUMmONS SIS ELASTOMERS MAJOR EQUIPMENT SIS ELASTOMERS UTlLlTlESSUMMARY l SIS ELASTOMERS STREAM FLOWS., SIS ELASTOMERS TOTAL CAPlTAL INVESTMENT SIS ELASTOMERS CAPlTAL INVESTMENT BY SECTlON SIS ELASTOMERS PRODUCTlON COSTS SIS ELASTOMERS DIRECT COSTS BY SECTlON ($1,OOO/YR) STYRENE-BUTADIENE RESIN PATENT SUMMARY *... A STYRENE-BUTADIENE RESIN DESIGN BASES AND ASSUMPTlONS STYRENE-BUTADIENE RESIN MAlOREQUlPMENT bc-

11 TABLES (Continued) 6.4 SlYRENE-BUTADIENE RESIN UTlLlTlES SUMMARY SlYRENE-BUTADIENE RESIN STREAM FLOWS SIYRENE-BUTADIENE RESIN TOTAL CAPlTAL INVESTMENT l STYRENE-BUTADIENE RESIN CAPITAL INVESTMENT BY SECTlON STYRENE-BUTADIENE RESIN PRODUCTION COSTS STYRENE-BUTADIENE RESIN DIRECT COSTS BY SECTlON ($1,OOO/YR) SlYRENE-MALEIC ANHYDRIDE COPOLYMER PA~SUMMARY... A BIYRENE-MALEIC ANHYDRIDE RESIN DESIGN BASES AND ASSUMFTlONS SIYRENE-MALEIC ANHYDRIDE RESIN MAJOR EQUIPMENT SlYRENE-MALEIC ANHYDRIDE RESIN UTlLlTlES SUMMARY SlYRENE-MALEIC ANHYDRIDE RESIN SlREAM FLOWS , S WRENE-MALElC ANHYDRIDE RESIN TOTAL CAPlTAL INVESTMENT.....,..., SlYRENE-MALEIC ANHYDRIDE RESIN CAPITAL INVESTMENT BY SECTION , l SIYRENE-MALEIC ANHYDRIDE RESIN PRODUCllON COSTS l STYRENE-MALEIC ANHYDRIDE RESIN DIRECT COSTS BY SECTlON ($1,OOO/YR) l STYRENE-MALEIC ANHYDRIDE RESIN PRODUCTlON COSTS FOR MAJOR GRADES X-

12 TABLES (ContImed) 8.1 MElHACRYlATE-BUTADIENE-SlYRENE PATENT SUMMARY A METHACRYLATE-BUTADIENE-SlYRENE DESIGN BASES AND ASSUMPTlONS MEl HACRYlATE-BUTADIENE-STYRENE MAJOR EQUIPMENT METHACRYLATE-BUTADIENE-STYRENE UTlLlTlES SUMMARY MEIHACRYLATE-BUTADIENE-STYRENE STREAM FLOWS MElHACRYlATE-BUTADIENE-STYRENE TOTAL CAPITAL INVESTMENT METHACRYLATE-BUTADIENE-STYRENE CAPmAL INVESTMENT BY SECTlON MElHACRYlATE-BUTADIENE-SlYRENE PRODUCllON COSTS MEIHACRYLATE-BUTADIENE-SlYRENE DIRECT COSTS BY SECIlON ($1,OOO/YR) c.1 SNRENIC BLOCK COPOLYMER ELASTOMERS PRODUCT INFORMATlON c-3 C.2 STYRENIC BLOCK COPOLYMER ELASTOMERS TYPICAL PROPERTlES OF PRODUCTS C-6 C.3 SlYRENlC BLOCK COPOLYMER RESINS NOMINAL PHYSICAL PROPERTlES OF K-RESIN KROl POLYMER C-10 C.4 SIYRENIC BLOCK COPOLYMER RESINS NOMINAL PHYSICAL PROPERTlES OF KRO3-5 POLYMER..... C-l 1 c.5 SIYRENIC BLOCK COPOLYMER RESINS NOMINAL PHYSICAL PROPEFITIES OF K-RESINQ KRlO FILM c-12 C.8 SlYRENE-MALEIC ANHYDRIDE (SMA) RESINS DYLARK@ RESIN TRANSPARENT GRADES c-13 C.7 SlYRENE-MALEIC ANHYDRIDE (SMA) RESINS DYLARK@ RESIN IMPACT GRADES c-14 - xl -

13 TABLES (Concluded) C.8 STYRENE-MALElC ANHYDRIDE (SMA) RESINS RESIN GLASS REINFORCED IMPACT GRADES c-15 C.9 METHACRYLATE-BUTADIENE-SIYRENE (MBS) , C-l 6 - xii -