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Bisphenol A
PEP Report 192A
Published July 2014
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درباره گزارش Bisphenol A
Published July 2014
Bisphenol A (BPA), a key intermediate in the phenol value chain, is produced by the condensation reaction between phenol and acetone. It is primarily consumed during the production of polycarbonates and epoxy resins which are used in construction, the automotive industry, and in a variety of household items. BPA was traditionally produced using strong mineral acid catalysts. However, more demanding applications, along with the need for environmentally benign processes have led to the replacement of nearly all the strong mineral acids with cation exchange resin catalysts. The product is typically isolated and purified from the reactor effluent using one or more crystallization processes. Moreover, the solvents and unreacted acetone are purified using distillation and recycled. A large excess of phenol is used to achieve higher BPA selectivity and hence, it is prevalent throughout the process layout.
دانلود گزارش اتانول آمین ها
بیسفنول A (BPA)، یک واسطه کلیدی در زنجیره ارزش فنل، از واکنش تراکم بین فنل و استون تولید می شود. این ماده عمدتاً در هنگام تولید پلی کربنات ها و رزین های اپوکسی که در ساخت و ساز، صنعت خودروسازی و در انواع اقلام خانگی استفاده می شود، مصرف می شود. BPA به طور سنتی با استفاده از کاتالیزورهای اسید معدنی قوی تولید می شد. با این حال، کاربردهای بیشتر، همراه با نیاز به فرآیندهای بی خطر برای محیط زیست، منجر به جایگزینی تقریباً تمام اسیدهای معدنی قوی با کاتالیزورهای رزین تبادل کاتیونی شده است. محصول معمولاً با استفاده از یک یا چند فرآیند کریستالیزاسیون از پساب راکتور جدا و خالص می شود. علاوه بر این، حلال ها و استون واکنش نداده با استفاده از تقطیر خالص شده و بازیافت می شوند. مقدار زیادی از فنل برای دستیابی به گزینش BPA بالاتر استفاده می شود و از این رو، در سراسر طرح فرآیند رایج است.
فهرست مطالب Bisphenol A
Contents
Contents ……………………………………………………………………………………………………………………………………. iii
Figures ……………………………………………………………………………………………………………………………………… vi
Tables ………………………………………………………………………………………………………………………………………. vii
1. Introduction ………………………………………………………………………………………………………………………….. 1-1
2. Conclusions ………………………………………………………………………………………………………………………….. 2-1
3. Executive Summary ………………………………………………………………………………………………………………. 3-1
Commercial overview ……………………………………………………………………………………………………………. 3-1
Technology overview …………………………………………………………………………………………………………….. 3-2
Process economics …………………………………………………………………………………………………………………. 3-2
4. Industry status ………………………………………………………………………………………………………………………. 4-1
Uses …………………………………………………………………………………………………………………………………….. 4-1
Supply and demand ……………………………………………………………………………………………………………….. 4-2
Capacities …………………………………………………………………………………………………………………………….. 4-2
Health concerns and regulatory issues ……………………………………………………………………………………… 4-4
Worldwide producers of BPA …………………………………………………………………………………………………. 4-5
Planned worldwide capacities …………………………………………………………………………………………………. 4-6
Feedstock ……………………………………………………………………………………………………………………………… 4-7
Phenol ………………………………………………………………………………………………………………………………. 4-7
Acetone …………………………………………………………………………………………………………………………….. 4-7
BPA product ……………………………………………………………………………………………………………………… 4-8
Feedstock and product specifications ……………………………………………………………………………………….. 4-9
Phenol ………………………………………………………………………………………………………………………………. 4-9
Acetone …………………………………………………………………………………………………………………………….. 4-9
BPA product ……………………………………………………………………………………………………………………… 4-9
5. Chemistry review ………………………………………………………………………………………………………………….. 5-1
Process Chemistry …………………………………………………………………………………………………………………. 5-1
Condensation reactions ……………………………………………………………………………………………………….. 5-1
Cracking reactions ……………………………………………………………………………………………………………… 5-2
Rearrangement reactions …………………………………………………………………………………………………….. 5-3
Production process ………………………………………………………………………………………………………………… 5-4
Condensation reactors …………………………………………………………………………………………………………. 5-4
Condensation catalysts ………………………………………………………………………………………………………… 5-4
Product recovery and purification…………………………………………………………………………………………. 5-5
Patent review ………………………………………………………………………………………………………………………… 5-7
Badger ………………………………………………………………………………………………………………………………. 5-7
Bayer ………………………………………………………………………………………………………………………………… 5-8
Dow …………………………………………………………………………………………………………………………………. 5-8
Idemitsu/Chiyoda ……………………………………………………………………………………………………………….. 5-9
Mitsui ……………………………………………………………………………………………………………………………… 5-10
SABIC (GE) ……………………………………………………………………………………………………………………. 5-10
IHS Chemical Process Economics Program | Report 192A
Sinopec/Lummus ……………………………………………………………………………………………………………… 5-12
6. Bisphenol A by SABIC process ………………………………………………………………………………………………. 6-1
Process description ………………………………………………………………………………………………………………… 6-1
Reaction ……………………………………………………………………………………………………………………………. 6-1
Product separation and recovery …………………………………………………………………………………………… 6-1
Cracking and rearrangement ………………………………………………………………………………………………… 6-2
BPA purification ………………………………………………………………………………………………………………… 6-3
Process discussion …………………………………………………………………………………………………………………. 6-7
Patent selection ………………………………………………………………………………………………………………….. 6-7
Catalyst …………………………………………………………………………………………………………………………….. 6-7
Reactors ……………………………………………………………………………………………………………………………. 6-7
Feedstocks ………………………………………………………………………………………………………………………… 6-7
BPA recovery ……………………………………………………………………………………………………………………. 6-8
Materials of construction …………………………………………………………………………………………………….. 6-8
Waste treatment …………………………………………………………………………………………………………………. 6-8
Cost estimates ……………………………………………………………………………………………………………………… 6-12
Fixed-capital costs ……………………………………………………………………………………………………………. 6-12
Production costs ……………………………………………………………………………………………………………….. 6-12
7. Bisphenol A by Dow process ………………………………………………………………………………………………….. 7-1
Process description ………………………………………………………………………………………………………………… 7-1
Reaction ……………………………………………………………………………………………………………………………. 7-1
Product separation and recovery …………………………………………………………………………………………… 7-1
Cracking and rearrangement ………………………………………………………………………………………………… 7-2
BPA purification ………………………………………………………………………………………………………………… 7-2
Process discussion …………………………………………………………………………………………………………………. 7-6
Patent selection ………………………………………………………………………………………………………………….. 7-6
Catalyst …………………………………………………………………………………………………………………………….. 7-6
Reactors ……………………………………………………………………………………………………………………………. 7-6
Feedstocks ………………………………………………………………………………………………………………………… 7-6
BPA recovery ……………………………………………………………………………………………………………………. 7-7
Materials of construction …………………………………………………………………………………………………….. 7-7
Waste treatment …………………………………………………………………………………………………………………. 7-7
Cost estimates ……………………………………………………………………………………………………………………… 7-11
Fixed-capital costs ……………………………………………………………………………………………………………. 7-11
Production costs ……………………………………………………………………………………………………………….. 7-11
8. Bisphenol A by Badger process ………………………………………………………………………………………………. 9-1
Process description …………………………………………………………………………………………………………….. 9-1
Reaction ………………………………………………………………………………………………………………………… 9-1
Product separation and recovery ……………………………………………………………………………………….. 9-1
Cracking and rearrangement …………………………………………………………………………………………….. 9-2
BPA purification …………………………………………………………………………………………………………….. 9-2
Process discussion ……………………………………………………………………………………………………………… 9-6
Patent selection ………………………………………………………………………………………………………………. 9-6
Catalyst check ………………………………………………………………………………………………………………… 9-6
Reactors …………………………………………………………………………………………………………………………. 9-6
Feedstocks ……………………………………………………………………………………………………………………… 9-6
BPA recovery …………………………………………………………………………………………………………………. 9-7
Materials of construction …………………………………………………………………………………………………. 9-7
Waste treatment ………………………………………………………………………………………………………………. 9-7
Cost estimates ………………………………………………………………………………………………………………….. 9-11
Fixed-capital costs …………………………………………………………………………………………………………. 9-11
Production costs ……………………………………………………………………………………………………………. 9-11
Appendix A: Patent summary table ……………………………………………………………………………………………. 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 diagrams …………………………………………………………………………………………… E-1
IHS Chemical Process Economics Program | Report 192A
Figures
Figure 3.1: Capital costs comparison …………………………………………………………………………………………… 3-5
Figure 3.2: Production costs comparison ……………………………………………………………………………………… 3-6
Figure 3.3: CO2 emissions comparison ……………………………………………………………………………………….. 3-7
Figure 3.4: Water usage comparison ……………………………………………………………………………………………. 3-7
Figure 4.1: Global consumption by end uses ………………………………………………………………………………… 4-1
Figure 4.2: Worldwide supply and demand ………………………………………………………………………………….. 4-2
Figure 4.3: Global capacity by process type …………………………………………………………………………………. 4-2
Figure 4.4: Capacity growth by process type ………………………………………………………………………………… 4-3
Figure 4.5: Capacity growth by regions ……………………………………………………………………………………….. 4-4
Figure 4.6: Historical prices for phenol ……………………………………………………………………………………….. 4-7
Figure 4.7: Historical prices for acetone ………………………………………………………………………………………. 4-8
Figure 4.8: Historical prices for BPA ………………………………………………………………………………………….. 4-8
Figure 6.1: Bisphenol A production by SABIC process ………………………………………………………………… E-2
Figure 6.2: Effect of feedstock prices (SABIC process) ……………………………………………………………….. 6-14
Figure 6.3: Effect of plant capacity (SABIC process) ………………………………………………………………….. 6-14
Figure 7.1: Bisphenol A production by Dow process ……………………………………………………………………. E-3
Figure 7.2: Effect of feedstock prices (Dow process) …………………………………………………………………… 7-13
Figure 7.3: Effect of plant capacity (Dow process) ……………………………………………………………………… 7-13
Figure 8.1: Bisphenol A production by Badger process ………………………………………………………………… E-4
Figure 8.2: Effect of feedstock prices (Badger process) ……………………………………………………………….. 9-13
Figure 8.3: Effect of plant capacity (Badger process) …………………………………………………………………… 9-13
IHS Chemical Process Economics Program | Report 192A
July 2014
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© 2014 IHS
Tables
Table 3.1: Production economics comparison (English units) …………………………………………………………. 3-3
Table 3.2: Production economics comparison (Metric units) ………………………………………………………….. 3-4
Table 4.1: Worldwide producers of BPA ……………………………………………………………………………………… 4-5
Table 4.2: Planned worldwide capacities ……………………………………………………………………………………… 4-6
Table 4.3: Phenol feedstock specifications …………………………………………………………………………………… 4-9
Table 4.4: Acetone feedstock specifications …………………………………………………………………………………. 4-9
Table 4.5: BPA product specifications ………………………………………………………………………………………… 4-9
Table 6.1: Design basis and assumptions (SABIC process) ……………………………………………………………. 6-4
Table 6.2: Stream flows (SABIC process) ……………………………………………………………………………………. 6-5
Table 6.3: Major equipment (SABIC process) ……………………………………………………………………………… 6-9
Table 6.4: Utilities summary (SABIC process) …………………………………………………………………………… 6-11
Table 6.5: Total capital investment (SABIC process) ………………………………………………………………….. 6-15
Table 6.6: Production costs (SABIC process) …………………………………………………………………………….. 6-16
Table 6.7: Production costs in metric units (SABIC process) ……………………………………………………….. 6-18
Table 7.1: Design basis and assumptions (Dow process) ……………………………………………………………….. 7-3
Table 7.2: Stream flows (Dow process) ……………………………………………………………………………………….. 7-4
Table 7.3: Major equipment (Dow process) …………………………………………………………………………………. 7-8
Table 7.4: Utilities summary (Dow process) ………………………………………………………………………………. 7-10
Table 7.5: Total capital investment (Dow process) ……………………………………………………………………… 7-14
Table 7.6: Production costs (Dow process) ………………………………………………………………………………… 7-15
Table 7.7: Production costs in metric units (Dow process) …………………………………………………………… 7-17
Table 8.2: Stream flows (Badger process) ……………………………………………………………………………………. 9-4
Table 8.3: Major equipment (Badger process) ………………………………………………………………………………. 9-8
Table 8.4: Utilities summary (Badger process)……………………………………………………………………………. 9-10
Table 8.5: Total capital investment (Badger process) …………………………………………………………………… 9-14
Table 8.6: Production costs (Badger process) ……………………………………………………………………………… 9-15
Table 8.7: Production costs in metric units (Badger process) ………………………………………………………… 9-17
Table A.1: Bisphenol A production patent summary…………………………………………………………………….. A-2