PROCESS ECONOMICS PROGRAM

SRI INTERNATIONAL

Menlo Park, California 94025 Abstract

Process Economics ProgramReport No. 155

ETHYLENECOPOLYMERS

(March 1983)

This report coversthe 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 - Report No. 155 l ETHYLENE COPOLYMERS

by MICHAEL ARNE ROBERT H. SCHWAAR

March 1983

A private report by the PROCESS ECONOMICS PROGRAM

Menlo Park, California 94025 -. -.

For detailed marketing data and information, the reader is referred to one of the SRI programs specializing in marketing research. The CHRMICALECONOMICS HANDBOOK Program covers most major chemicals and chemical products produced in the United States and the WORLDPETROCHRMICALS Program covers major hydrocarbons and their derivatives.on a worldwide basis. In addition, the SRI DIRECTORYOF CHEMICALPRODUCERS services provide detailed lists of chemical producers by company, prod- uct, and plant for the United States and Western Europe.

ii CONTENTS

1 INTRODUCTION ...... 1

2 SUMMARY ...... 3 Ethylene-Vinyl Acetate ...... 3 Ethylene-MethacrylicAcid Ionomer ...... 6 0- Ethylene-Methyl Acrylate ...... 7 Ethylene-Carbon Monoxide ...... 7

3 INDUSTRY STATUS ...... 9 Ethylene-Vinyl Acetate 9 Ethylene-MethacrylicAcid Ionomer ...... 10 Ethylene-Methyl Acrylate ...... 11 Ethylene-Acrylic Acid ...... 12 Ethylene-Ethyl Acrylate ...... 12

4 ETRTLENR-VINYL ACETATE COPOLYMERS ...... 15 Chemistry ...... '...... 15 Process Review ...... 16 Process Description ...... 20 Polymerization and Recovery ...... 22 Finishing ...... 23 Process Discussion ...... 28 Polymerization and Recovery ...... 28 Finishing ...... ; ...... 29 Materials of Construction ...... 30 Feed Specifications ...... 30 Waste Streams ...... 30 Cost Estimates ...... 31 Capital Costs ...... 31 Production Costs ...... 31

5 ETRYLENE-METHACRYLICACID IONOMERS ...... 41 Chemistry ...... 41 Process Review 43 Process Description ...... 47 Polymerization and Recovery ...... ,...... 49 Naturalization and Finishing ...... 50 Process Discussion ...... 54 Polymerization and Recovery ...... 54

iii CONTENTS

5 ETHYLENE-METHACRYLIC ACID IONOMERS (Continued) Neutralization and Finishing ...... 55 Materials of Construction ...... 55 Feed Specifications ...... 55 Waste Streams ...... :i Cost Estimates ...... Capital Costs ...... 56 Production Costs ...... 57

6 ETHYLENE-METHYL ACRYLATECOPOLYMERS ...... 65 Chemistry ...... ;6' Process Review...... Process Description ...... 69 Polymerizatien and Recovery ...... 69 Finishing ...... 3: Process Discussion ...... Polymerization and Recovery ...... 76 Finishing ...... :: Materials of Construction ...... Feed Specifications ...... 77 Waste Streams ...... 77 Cost Estimates...... ;i Capital Costs ...... Production Costs ...... 78

7 ETHYLENE-CARBON MONOXIDE COPOLYMERS ...... 89 Chemistry ...... 89 Process Review...... 90 Conclusions ...... 94

APPENDIX A PHYSICAL PROPERTIES OF ETHYLENE COPOLYMERS . . . . 97

CITED REFERENCES ...... 99

PATENTREFERENCES BY COMPANY . . . , ...... 103

IV ILLUSTRATIONS

4.1 Ethylene-Vinyl Acetate Copolymer Flow Sheet...... :. , ...... 105 4.2 Ethylene-Vinyl Acetate Copolymer Product Value as a Function of Vinyl Acetate Content . , . . 39 Ethylene-Vinyl Acetate Copolymer Effect of,Operating Level and Plant Capacity on Product Value ...... 40 5.1 Ethylene-Methacrylic Acid Ionomer Flow Sheet...... 107 5.2 Ethylene-Methacrylic Acid Ionomer Effect of Operating Level and Plant Capacity on Product Value ...... 64 6.1 Ethylene-Methyl Acrylate Copolymer Flow Sheet...... 113 6.2 Ethylene-Methyl Acrylate Copolymer Product Value as a Function of Ethylene Feedstock Price . . 86 6.3 Ethylene-Methyl Acrylate Copolymer Effect of Operating Level and Plant Capacity 0n Product Value...... 87

V TABLES

2.1 Summary of Ethylene Copolymer Economics ...... 5 3.1 U.S. Manufacturers of Ethylene Copolymers ...... 13 -3.2 Japanese Manufacturers of Ethylene Copolymers ...... 14 4.1 Ethylene-Vinyl Acetate Copolymer Patent Sunmary ...... 17 4.2 Ethylene-Vinyl Acetate Copolymer Design Bases ...... 21 4.3 Ethylene-Vinyl Acetate Copolymer Stream Flows ...... 25 4.4 Ethylene-Vinyl Acetate Copolymer Major Equipment...... 26 4.5 Ethylene-Vinyl Acetate Copolymer Capital Investment ...... 33 4.6 Ethylene-Vinyl Acetate Copolymer Major Equipment Costs ...... 35 4.7 Ethylene-Vinyl Acetate Copolymer Production Costs ...... 36 5.1 Ethylene-Methacrylic Acid Ionomer Patent Summary ...... 44 5.2 Ethylene-MethacrylicAcid Ionomer Design Bases ...... 48 5.3 Ethylene-MethacrylicAcid Copolymer Ionomer Stream Flows ...... 51 5.4 Ethylene-MethacrylicAcid Ionomer Major Equipment ...... 52 5.5 Ethylene-MethacrylicAcid Ionomer Capital Investment ...... 58 5.6 Ethylene-MethacrylicAcid Ionomer Major Equipment Costs ...... 60 5.7 Ethylene-MethacrylicAcid Ionomer Production Costs ...... 61 6.1 Ethylene-Methyl Acrylate Copolymer Patent Summary ...... 67

Vii TABLES

6.2. Ethylene-Methyl Acrylate Copolymer Copolymerization Reaction Data ...... 68. 6.3 Ethylene-Methyl Acrylate Copolymer Design Bases ...... 70 6.4 Ethylene-Methyl Acrylate Copolymer Stream Flows...... 73 6.5 Ethyleqe-Methyl Acrylate Copolymer Major Equipment ...... 74 6.6 Ethylene-Methyl Acrylate Copolymer Capital Investment ...... 6.7 Ethylene-Methyl Acrylate Copolymer Major Equipment Costs ...... 82

6,8 Ethylene-Methyl Acrylate Copolymer Production Costs ...... 83 7.1 Ethylene-Carbon Monoxide Copolymer Patent Summary . . . . i ...... 9%

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