Process Economics Program Report 39D
Published: Dec-2001
This report evaluates recent developments in technologies
for polystyrene production. We provide preliminary designs and economics for
both general purpose polystyrene (GPPS) and high impact polystyrene (HIPS) by
current commercial processes and by the emerging technology using anionic polymerization.
In the past, the almost explosive polymerization rate
and tendency to form gels have hindered the commercialization of anionic technology.
New technology is now available which eliminates these two stumbling blocks
and allows production of superior products with superior economics.
For GPPS production, the total capital investment of
the anionic process is about 85% of that for a comparable free radical process,
and has the potential to be further improved. The product produced anionically
is a cleaner resin, having none of the usual dimer and trimer content and a
very low residual styrene content (10 ppm or lower, compared to several hundred
ppm for conventional processes). In addition, the anionic product has better
strength and processability, as well as considerable capability for more improvements
in the future.
For HIPS production, new emulsion techniques are used
to produce a rubber concentrate that can be incorporated into the anionic GPPS
to produce anionic HIPS. This combined technology has similar total capital
to conventional HIPS, but about 10% less raw material costs. The emulsion technology
allows superior control of rubber particle size and microstructure. The use
of anionic GPPS as a base adds its improvements in processability, strength,
and “cleanliness”.
Recent innovations are also incorporated into our conceptual
designs for GPPS and HIPS processes by free radical polymerization. These innovations
provide for improved heat management techniques, improved recycle handling and
better rubber particle size control.
The Report also discusses the current status of the polystyrene
industry. We provide data on historical and projected world polystyrene capacity,
production and consumption by region, end uses, and producing companies worldwide.
Other PEP Related Reports
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