Production Cost Report | Other

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Carbon Fibre Production Cost Breakup From Polyacrylonitrile and Rayon Mixture

Details: Germany - based plant Q2 2024  | From $ USD

This report entails a detailed cost evaluation of carbon fibre production from rayon and polyacrylonitrile. The manufacturing process of carbon fibre begins with the complex sequential process of combining the strands of polymer varieties, i.e., polyacrylonitrile and rayon. Initially, the polymers are combined, passing through a spinning and stabilization process that improves the bonding ability in the fiber strands. It is then passed through surface treatment, where the fibres are oxidized in the presence of oxygen and then coated and wounded into fiber bobbins carrying carbon fiber as the final product.

Top Producers of Carbon Fibre

  • A&P Technology Inc.
  • Formosa Plastics Corporation
  • DowAksa USA LLC
  • Anshan Sinocarb Carbon Fibers Co. Ltd
  • Hexcel Corporation

Feedstock for Carbon Fibre

Carbon fibre is made up of organic polymer varieties, specifically polyacrylonitrile and rayon as its major feedstock. The procurement of carbon fiber is largely dependent upon factors, including its production cost, market prices, supply chain stability, etc. Moreover, other factors such as the availability of its raw materials (acrylonitrile for polyacrylonitrile production along with rayon that serves as the feedstock for carbon fibre), as well as its demand for aircraft, spacecraft, automotive parts, and boats production altogether influences its overall procurement. Similarly, laws, regulations, governmental policies, and socioeconomic conditions have a major impact on procurement across borders.

The project economic analysis provided in the report discusses a Germany-based plant:

  • Manufacturing Process
    • Process Flow
    • Material Flow
    • Material Balance
  • Raw Material and Product's Specifications
    • Raw Material Consumption
    • Product and Co-Product Generation
    • Capital Investment
  • Land and Site Cost
    • Offsites/Civil Works
    • Equipment Cost
    • Auxiliary Equipment Cost
    • Contingency
    • Engineering and Consulting Charges
    • Working Capital
  • Variable Cost
    • Raw Material
    • Utilities
  • Fixed Cost
    • Labor Requirement & Wages
    • Overhead Expenses
    • Maintenance Charges
  • Financing Costs
    • Interest on Working Capital
    • Interest on Loans
  • Depreciation Charges
  • General Sales and Admin Costs
  • Production Cost Summary
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Report Content

Key Process Information

Evaluation of significant technical parameters along with process descriptions such as:

  • Consumption of Raw Material
  • Product Creation
  • Block Flow Diagram
  • Description of the Manufacturing Facility

Utilities Consumption

Evaluation of utilities consumed during the entire process based on:

  • Consumption per unit of product generated
  • Utility cost split and share of each utility in the total cost

Process Flow Diagram

Representation of various operations involved including:

  • Step-wise process
  • Utility consumption in each operation

Capital Cost Analysis

In-depth analysis of costs involved in setting up a new manufacturing unit, including:

  • Cost of Building a Process Unit
  • Cost of Setting Up the Infrastructure
  • Working Capital
  • Commissioning & Start-Up of the Plant

Implementation Schedule

Time frame of the project design, which includes:

  • Plant Start-Up
  • Plant Construction
  • Engineering Fundamentals
  • Raw Material Procurement

Construction Cost Details

Detailed analysis of costs involved in the operation of various functional units in the process unit and infrastructure.

Operating Cost Analysis

Evaluation of costs associated with the production of the final product, namely:

  • Procurement of Raw Materials
  • Consumption of Utilities
  • Fixed Costs
  • Depreciation

Economic Analysis

Analysis of the way in which process economics are impacted by plant capacity.

  • Construction Cost
  • Working Capital
  • Fixed and Variable Operating Costs
  • Corporate Overhead
  • Depreciation

Customized Analyses

Detailed cost estimates of any industrial plant depending on your requirements, including plant capacity and location as per the need.

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