Process Economics Program

Transcription

1 IHS Chemical Process Economics Program Report 64A Solution Styrene-Butadiene Rubber By Girish Ballal

2 IHS Chemical 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 IHS Chemical 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 IHS Chemical, 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 IHS Chemical pursuant to this agreement. For detailed marketing data and information, the reader is referred to one of the IHS Chemical programs specializing in marketing research. THE IHS CHEMICAL ECONOMICS HANDBOOK Program covers most major chemicals and chemical products produced throughout the world. In addition the IHS DIRECTORY OF CHEMICAL PRODUCERS services provide detailed lists of chemical producers by company, product, and plant for the United States, Europe, East Asia, China, India, South & Central America, the Middle East & Africa, Canada, and Mexico. July IHS

3 PEP Report 64A Solution Styrene-Butadiene Rubber By Girish Ballal July 2013 Abstract Styrene-butadiene rubber is currently the largest volume synthetic rubber, which is produced by the copolymerization of styrene and butadiene by either the emulsion or solution process. Although the emulsion process is clearly the current capacity leader, the solution process has better future potential due to versatility and flexibility in imparting desired polymer structure. The current focus on high performance and green tires, as well as the current and upcoming government regulations regarding tire labeling, have contributed significantly to the increased popularity of the solution process. In this PEP Report, we review the current technologies for solution processes for styrene-butadiene rubbers. The emphasis is on developments since the late 1990s, after the publication of our earlier PEP Review on this topic. The process economics are developed in this PEP Report for producing 50,000 mt/year of SBR elastomer by commercial processes based on the patents of three companies. While the processes are PEP s independent interpretation of the companies patent literature and may not reflect in whole or in part the actual plant configuration, we do believe that they are sufficiently representative of the processes to estimate the plant economics within the range of accuracy for economic evaluations of the conceptual process designs. July IHS

4 Contents 1. Introduction Conclusion Summary Commercial overview Technology Process economics Industry status Uses Supply and demand Capacities Tire labeling regulations Worldwide producers of solution SBR Planned worldwide capacities Feedstocks Styrene Butadiene Solvent SBR product Chemistry review Solution SBR process Chemistry Initiation Propagation Termination Copolymerization Living polymerization Polymer blending Polymer structure and properties Polymer-chain functionalization Polymer recovery and processing Patent review Versalis Bridgestone Lanxess Goodyear Styron Phillips Solution SBR by Bridgestone process Process description Recipe preparation July 2013 iii 2013 IHS

5 Contents (continued) Polymerization Polymer processing Polymer properties Process discussion Patent selection Chemicals Reactors Polymer recovery Materials of construction Waste treatment Cost estimates Fixed-capital costs Production costs Solution SBR by Versalis process Process description Recipe preparation Polymerization Polymer processing Polymer properties Process discussion Patent selection Chemicals Reactors Polymer recovery Materials of construction Waste treatment Cost estimates Fixed-capital costs Production costs Solution SBR by Lanxess process Process description Recipe preparation Polymerization Polymer processing Polymer properties Process discussion Patent Selection Chemicals Reactors Polymer recovery July 2013 iv 2013 IHS

6 Contents (concluded) Materials of construction Waste treatment Cost estimates Fixed-capital costs 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 diagrams... E-1 July 2013 v 2013 IHS

7 Figures 4.1 Consumption pattern for SBR end uses Worldwide supply and demand for styrene-butadiene rubber Global synthetic rubber capacity by type Capacity growth for the styrene-butadiene rubbers Regional capacity growth for the solution styrene-butadiene rubber Sample European Union tire rating label Proposed US tire rating system label Historical prices for styrene Historical prices for butadiene Historical prices for cyclohexane Historical prices for solution styrene-butadiene rubber Historical prices for emulsion styrene-butadiene rubber Effect of polymer composition on tan delta Chain-end and backbone functionalization Effect of extent of functionalization on tan delta Solution SBR by Bridgestone process Process flow diagram... E Solution SBR by Bridgestone process Production costs vs. plant capacity Solution SBR by Versalis process Process flow diagram... E Solution SBR by Versalis process Production costs vs. plant capacity Solution SBR by Lanxess process Process flow diagram... E Solution SBR by Lanxess process Production costs vs. plant capacity July 2013 vi 2013 IHS

8 Tables 3.1 Production economics for the solution SBR processes in English units Production economics for the solution SBR processes in metric units Worldwide producers of solution SBR Planned worldwide capacities Chain-end and backbone functionalization Solution SBR by Bridgestone process Polymer properties Solution SBR by Bridgestone process Design basis and assumptions Solution SBR by Bridgestone process Stream flows Solution SBR by Bridgestone process Major equipment Solution SBR by Bridgestone process Utilities summary Solution SBR by Bridgestone process Total capital investment Solution SBR by Bridgestone process Production costs Solution SBR by Bridgestone process Production costs (metric) Solution SBR by Versalis process Polymer properties Solution SBR by Versalis process Design basis and assumptions Solution SBR by Versalis process Stream flows Solution SBR by Versalis process Major equipment Solution SBR by Versalis process Utilities summary Solution SBR by Versalis process Total capital investment Solution SBR by Versalis process Production costs Solution SBR by Versalis process Production costs (metric) Solution SBR by Lanxess process Polymer properties Solution SBR by Lanxess process Design basis and assumptions Solution SBR by Lanxess process Stream flows July 2013 vii 2013 IHS

9 Tables (concluded) 8.4 Solution SBR by Lanxess process Major equipment Solution SBR by Lanxess process Utilities summary Solution SBR by Lanxess process Total capital investment Solution SBR by Lanxess process Production costs Solution SBR by Lanxess process Production costs (metric) July 2013 viii 2013 IHS