Polyamide (Nylon) 6

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PEP Review 2012-13POLYAMIDE (NYLON) 6BySusan L. Bell(November 2012)ABSTRACTZimmer AG’s continuous two-stage polymerization process is widely licensed for theproduction of polyamide 6 (nylon 6). The polymerization of caprolactam with a catalyst isperformed in a two-stage process using two vertical tube reactors in series. The two-stageprocess reduces the polymerization reaction time and allows the production of medium to highviscosity polyamide 6, as required for tire cord-grade products. Polymer chips are formed with anunderwater granulator and transfer to an extraction unit. Caprolactam and oligomers extracted inwater from the polymer chips are recovered in the monomer recovery section. The polymer chipsare then dried. In this review, the process economics for polyamide 6 chip production using aprocess similar to the Zimmer continuous two-stage polymerization process are presented. Theevaluation was based on a single-line plant with a capacity of 90,000 TPA of polyamide 6 chips. 2012 IHSPEP Review 2012-13

A private report by theProcess EconomicsProgramReview No. 2012-13POLYAMIDE (NYLON) 6by Susan L. BellNovember 2012Santa Clara, California 95054

IHS Chemical agrees to assign professionally qualified personnel to the preparation ofthe Process Economics Program’s reports and will perform the work in conformance withgenerally 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 willassume any liability for the special or consequential damages arising from the Client’s use of theresults 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 orindirectly from the Client’s use of the reports or other deliverables produced by IHS Chemicalpursuant to this agreement.For detailed marketing data and information, the reader is referred to one of the IHSChemical programs specializing in marketing research. THE IHS CHEMICAL ECONOMICSHANDBOOK Program covers most major chemicals and chemical products produced throughoutthe world. In addition the IHS DIRECTORY OF CHEMICAL PRODUCERS services providedetailed 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 andMexico.

CONTENTSSUMMARY . 1INTRODUCTION . 3PROCESS REVIEW . 4PROCESS DESCRIPTION . 10Process Design . 10Section 100—Polymerization . 14Section 200—Monomer Recovery . 15PROCESS DISCUSSION. 15Material of Construction. 15Stream Factor . 15Caprolactam Raw Material . 16Reactor . 16Granulation and Extraction . 16Drying . 16Depolymerization . 16Waste Treatment . 16CAPITAL AND PRODUCTION COSTS . 16CITED REFERENCES . 27 2012 IHSiiiPEP Review 2012-13

FIGURES1Polyamide 6 Chip Production by a Process Similar to Zimmer ContinuousTwo-Stage Polymerization ProcessProcess Flow Diagram . 292Effect of Caprolactam Price on the Estimated Polyamide 6 Product Value . 26 2012 IHSivPEP Review 2012-13

TABLES1Process Economics of a Process Similar to Zimmer Polyamide 6 ProductionProcess . 22Recent Process Improvements in Polyamide 6 Chip Production . 33Recent Lurgi GmbH’s Zimmer Polyamide 6 Projects . 44Polyamide 6 ProductionPatent Summary . 75Polyamide 6 Chip Production by a Process Similar to Zimmer ContinuousTwo-Stage Polymerization ProcessDesign Bases and Assumptions . 116Polyamide 6 Chip Production by a Process Similar to Zimmer ContinuousTwo-Stage Polymerization ProcessStream Flows . 127Polyamide 6 Chip Production by a Process Similar to Zimmer ContinuousTwo-Stage Polymerization ProcessMajor Equipment . 188Polyamide 6 Chip Production by a Process Similar to Zimmer ContinuousTwo-Stage Polymerization ProcessUtilities Summary . 219Polyamide 6 Chip Production by a Process Similar to Zimmer ContinuousTwo-Stage Polymerization ProcessTotal Capital Investment . 2210Polyamide 6 Chip Production by a Process Similar to Zimmer ContinuousTwo-Stage Polymerization ProcessCapital Investment by Section . 2311Polyamide 6 Chip Production by a Process Similar to Zimmer ContinuousTwo-Stage Polymerization ProcessProduction Costs . 24 2012 IHSvPEP Review 2012-13

POLYAMIDE (NYLON) 6 By Susan L. Bell (November 2012) ABSTRACT Zimmer AG’s continuous two-stage polymerization process is widely licensed for the production of polyamide 6 (nylon 6). The polymerization of caprolactam with a catalyst is performed in a two-stage process using two vertical tube reactors in series.

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