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1- Introduction:
• Product description:
Unsaturated polyester resins are produced by the polycondensation of saturated and
unsaturated dicarboxylic acids with glycols.
Unsaturated polyester resins form highly durable structures and coatings when they are cross-
linked with a vinylic reactive monomer, most commonly styrene. The properties of cross-linked
UPR depend on the types of acids and glycols used and their relative proportions.
• Application:
The reinforced UPR are used in boat building, construction, transportation, and aircraft and
aerospace industries, and for consumer products, pipes, ducts, tanks, electrical products,
containers, trays, industrial housings, appliance, and miscellaneous items.
In the non-reinforced applications, UPR are used to produce buttons, body putty, clay pipe seal,
synthetic marble, floorings, and other miscellaneous products.
2- Market analysis:
Global consumption of unsaturated polyester resins have been more the 2 million metric
tons in 2002, and is estimated to grow with a high rate of 2-4% till 2006. North America (mainly
US) with consuming one third of world producing UPR is a greatest market, while Western
Europe, Japan and China are the main markets. Considering such a vast market, it is also notable
that the unsaturated polyester resin industry is mature, and critically depends on changing
market demand behavior and its interest toward durable products. Finally, balance of supply
and demand of unsaturated polyester resins in the world is shown as following.
800
400
200
0
North W. Europe China Japan Asia E. Europe Middle
America (other) East
Demand (1000MT)
60 57
1386 1391
50
39
40
31
28 29
30 26
20
10
0
Optimistic Average Pescimstic
Scenario
1
2.2. Competitors and their advantages compare to Iran
Concerning world producers of UPR, mostly four producers cover the North American market:
AOC, Reichhold, Interplastic. In Europe also DSM, Total Chemie, Ashland and Reichhold are major
producers.
These world-class producers of UPR have some agents in the Middle East area too.
Reichhold and Scott Boder have their agent in Dubai and American company of Ashland
cooperates with Saudi petrochemical sector in KSA. In Saudi Arabia, SIR Co. has the annual
capacity of 30000 MT for production of UPR and similar resins. Scott Boder in Dubai also can
supply about 18000 MT per year.
Middle
East
E.
Market Accessibility
Europe
Japan
Asia China
(other)
Market
Penetration
W.
Europe
N.
Low
America
Limited Markets
- +
Unsatisfied Demand
2
E. Euope &Central
Asia
China
Midle East
0 2 4
1000 MT
1.65
1.55
1.55 1.55
1.53 1.51 1.51
1.52
1.50
1.47
1.45 1.45
1.35
1.25
1.15
1997 1998 1999 2000 2001 2002 2003 2004 2005
Year
Based on these facts, the price, which can be determined for financial and economical
studies, will vary between $1-1.7/kg (depending on the grade) for local market and $1.3-1.7/kg
(depending on the grade) for export.
3
3- Technical analysis:
• Appropriate technology acquisition
Generally, commercial UPR are produced currently by.
1- Batch process: a) fusion method
b) Propylene oxide method
c) Solvent method
2- Continuous process: a) glycol method (fusion & solvent)
b) Propylene oxide method
4
Unsaturated polyester Resin Production
ESTERIFICATION
UNSATURATED
POLYESTER
POLYCONDENSATET
REACTIVE MONOMERS
STYRENE
METHYL METHACRYLATE
VINYL TOLUENE
PARA-METHYLSTYRENE
PROMOTERS/
INHIBITORS, ETC.
CROSS-LINKED
UNSATURATED
POLYESTERS
When the polycondensation is complete (as determined by acid number and the viscosity of a
specimen dissolved in styrene or other organic solvent), the resin is cooled to about 165ºC or
less. Hydroquinone (HQ) or a similar compound is added as an inhibitor and the mix is then
thinned with styrene, which is inhibited with HQ, toluhydroquinone (THQ) or mono-tertiary-butyl
hydroquinone. Occasionally, t-butyl catechol and p-benzoquinone are used as inhibitors.
All steps are carried out under a blanket of nitrogen, carbon dioxide or inert gas. The removal of
the water produced during the reaction is facilitated by a slow stream of inert gas though the
system. Depending on the composition of the “cook,” some operations use organic solvent to
remove water azeotropically, as is common practice in the preparation of alkyd resins.
5
Feed & catalysts & quantities:
Feed & catalysts consumption for production UPR
Consumption
Raw material Supply
(Kg/ Kg at product)
Arak petrochemical
Ethylene glycol 0.029
complex
Hydroquinone 0.0002 Import
Propylene oxide 0.191 Import
Farabi petrochemical
Phthalic anhydride 0.236
complex
Maleic anhydride 0.156 Import
Tabriz petrochemical
Styrene 0.4
complex / Import
6
Non- operating employee requirement
Section Number
Manager 5
Financial & Administrative 12
Maintenance & utilities 6
Services 12
Total 35
• Plant Capacity:
Plant capacity is 26000 tons/year of UPR via propylene oxide method (Batch process). This
capacity is based on market analysis and potential exports.
4- Financial analysis: