NYLON6 PROCESS ECONOMICS PROGRAM I. Report No. 41 A Supplement. by GRANT E. RUSSELL. July A private report by the PARK, CALIFORNIA

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1 Report No. 41 A Supplement NYLON6 by GRANT E. RUSSELL July 1976 A private report by the PROCESS ECONOMICS PROGRAM I STANFORD RESEARCH INSTITUTE MENLO I PARK, CALIFORNIA

2 For detailed marketing data and information, the reader is referred to one of the SRI programs specializing in marketing research. The CHEMICAL ECONOMICS HANDBOOK Program covers most major chemicals and chemical products produced in the United States and the WORLD HYDROCARBONS Program covers major hydrocarbons and their derivatives on a worldwide basis. In addition, the SRI DIRECTORY OF CHEMICAL PRODUCERS services provide detailed lists of chemical producers by company, product, and plant for the United States and Western Europe. ii

3 CONTENTS 1 INTRODUCTION SUMMARY... 3 Polymer Technology... 3 Polymer Costs... 4 Spinning... 5 Fiber Costs INDUSTRY STATUS... 9 Nylon Fibers in the United States Carpets Apparel Tire Cord 12 Plastics and RESINS IN THE UNITED STATES Capacities, Worldwide CHEMISTRY OF NYLON 6 PRODUCTION Water-Catalyzed Polymerization Kinetics Reequilibration 37 Anionic Polymerieatik' Kinetics Cationic Polymerization REVIEW OF PROCESSES Polymerization--General Water-Catalyzed Processed Chip Handling and Treatment Nylon 6 Waste Recovery Anionic Processes... Anionic Polymerizakk' ii33 Anionic Polymerization --Promoters and Cocatalysts Plastics and Resins Additives Additives ;o'il;lp;o;e'm;c;ra;li~a; ini &i&l PiO~eitiei 87 Additives to Improve Heat or Light Stability Additives to Improve Dyeability 110 Additives to Improve Antistatic Prip;r;ik Fiber Production vii

4 CONTENTS CONTINUOUS PROCESS FOR NYLON 6 CHIP... Process Description... Process Discussion... Cost Estimates... Capital InvestmZ... Production Costs... Chip for Plastics... POLYMER MELT FOR DIRECT SPINNING... Process Description... Process Discussion'... Coat Estimates... Capital Invest&n;... Production Costs... TEXTILE YARN PRODUCTION PROM NYLON 6 CHIP... Process Description--Spindrawing. Process Description- Partially Oriekld*Yki ini d~<e;t;r&. Cost Estimates... Capital InvestmHn;... Production Costs... TEXTILE YARN PRODUCTION BY DIRECT SPINNING... Cost Estimates... Capital InvestmZ... Production Costs... APPENDIX A DESIGN AND COST BASIS... APPENDIX B PHYSICAL DATA... APPENDIX C SAFETY AND HANDLING... APPENDIX D ACKNOWLEDGMENTS... SUPPLEMENTARY REFERENCES... CITED REFERENCES... PATENT REFERENCES BY COMPANY viii

5 ILLUSTRATIONS 6.1 Continuous Production of Nylon 6 Chip Flow Diagram Production of Nylon 6 Chip Effect of Plant Capacity on Total Fixed Capital Nylon Chip Process Effect of Operating Level and Plant Capacity on Production Cost Continuous Production of Nylon 6 Polymer Melt for Direct Spinning Flow Diagram Nylon 6 Polymer Melt for Direct Spinning Effect of Plant Capacity on Total Fixed Capital Nylon 6 Polymer for Direct Spinning Effect of Operating Level and Plant Capacity on Production Cost Yarn Production from Chip Flow Diagram Effect of Operating Level and Plant Capacity on Cost of Yarn Spun from Chip Effect of Operating Level and Plant Capacity on Cost of Yarn by Direct Spinning B.1 Vapor Pressure Caprolactam B.2 Specific Gravity, Caprolactam ix

6 TABLES 2.1 Comparison of Investment and Production (Transfer) Cost of Nylon 6 Chips with that of Vacuum Treated Nylon 6 Melt Production of 150 Denier Spindrawn Nylon 6 Yarn from Polymer Chips and Melt Production of 150 Denier Drawtextured Nylon 6 Yarn from Polymer Chips and Melt , U.S. Nylon Fibers Consumption by End Use U.S. Nylon Resins Consumption by End Use......, Nylon 6 Plants North America Nylon 6 Plants South America Nylon 6 Plants Western Europe Nylon 6 Plants CoIllmllnist Countries Nylon 6 Plants Africa, Asia, and Oceania Enthalpies and Entropies of Reaction Reaction Rate Constants Nylon 6--Water-Catalyzed Polymerization Summary of Patents Nylon 6--Chip Handling and Treatment Sunsnary of Patents Nylon 6--Waste Recovery Summary of Patents xi

7 TABLES Nylon 6--Anionic Polymerization Summary of Patents Nylon 6--Anionic Polymerizatiorr-Promoters and Cocatalysts Sunrnary of Patents Nylon 6--Plastics and Resins Summary of Patents Nylon 6--Additives to Improve Mechanical or Physical Properties Sumry of Patents Nylon 6--Additives to Improve Heat or Light Stability Summary of Patents Nylon 6--Additives to Improve Dyeability Summary of Patents..., Nylon 6--Additives to Improve Antistatic Properties Swnnary of Patents Nylon 6--Fiber Production Summary of Patents Nylon 6--Bicomponent Fibers Summary of Patents Continuous Production of Nylon 6 Chip Stream Flows e Continuous Production of Nylon 6 Chip Major Equipment and Utilities Summary Continuous Production of Nylon 6 Chip Total Capital Investment Continuous Production of Nylon 6 Chip Production Costs Production of Nylon 6 Polymer Melt for Direct Spinning Stream Flows : xii

8 TABLES 7.2 Production of Nylon 6 Polymer Melt for Direct Spinning Major Equipment and Utilities Summary Production of Nylon 6 Polymer Melt for Direct Spinning Total Capital Investment Nylon 6 Polymer Melt for Direct Spinning Production Costs Yarn Production (150 Denier) from Nylon 6 Chip Total Capital Investment Continuous Filament 150 Denier Yarn from Chip--Spindrawing Process Production Costs Continuous Filament 150 Denier Textured Yarn from Chip-- Partially Oriented Yarn, Drawtexturing Process Production Costs Yarn Production (150 Denier) by Direct Spinning Total Capital Investment Continuous Filament 150 Denier Yarn by Direct Spinning-- Spindrawing Process Production Costs Continuous Filament 150 Denier Textured Yarn by Direct Spinning--Partially Oriented Yarn, Drawtexturing Process Production Costs B.l Physical Properties of Caprolactam B.2 Physical Properties of Nylon B.3 Properties of Polyamide Fibers xiii

PROCESS ECONOMICS PROGRAM

PROCESS ECONOMICS PROGRAM SRI INTERNATIONAL Abstract Process Economics Program Report No. 83A Menlo Park, California 94025 ADHESIVES (January 1986) This report reviews the technology and summarizes relevant