Bimodal HDPE from Ethylene and 1-Butene (Similar to BORSTAR)
HDPE Production Costs Report | Issue D | Q4 2024
| Report Details |
| 350 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 350 kta (kilo metric ton per annum) United States-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.
Report Abstract
This report presents the economics of Bimodal High Density Polyethylene (HDPE) production from polymer grade (PG) ethylene and 1-butene in the United States. The process examined in this report uses a slurry loop process similar to Borealis BORSTAR. The reaction system consists of a slurry loop and a gas phase reactor.
The report provides a comprehensive study of HDPE production and related HDPE production cost, covering three key aspects: a complete description of the HDPE production process examined; an in-depth analysis of the related HDPE plant capital cost (Capex); and an evaluation of the respective HDPE plant operating costs (Opex).
The HDPE production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The HDPE plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The HDPE plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Process Schematic
The process under analysis comprises four major sections: (1) Feed Preparation; (2) Polymerization; (3) Separation; and (4) Finishing.
Feed Preparation. Fresh polymer grade (PG) ethylene provided via a pipeline from a nearby facility and butene are passed through fixed-bed adsorption systems, in which potential catalyst poisons such as water, oxygen and other polar impurities are removed from the monomers before feeding the reactors.
Polymerization. The prepolymerizer is a small loop reactor in which the catalyst mixture, part of the purified monomers and hydrogen are mixed to form a protective shell around the catalyst particles - this prevents the catalysts from breaking downstream. The prepolymerized catalyst is sent to the loop reactor, where the ethylene polymerization takes place in a propane-diluent slurry under supercritical conditions. The slurry is continuously discharged to a flash chamber, for removing unreacted monomers. The resulting slurry is transferred along with fresh ethylene, butene and hydrogen to a gas-phase reactor for further polymerization. The gas-phase reactor is a fluidized-bed reactor, which allows the production of heavy copolymers, with broader molecular-weight distribution.
Separation. The separated gaseous hydrocarbon stream from flash chamber is fed to three distillation columns in order to separate propane, unreacted butene and ethylene.
Finishing. The polymer powder is fed to a purge bin, where residual hydrocarbons are removed and the catalyst is deactivated by treatment with hot nitrogen and steam. The polymer powder from the degasser, additives and antiblocks are fed to a pelletizing system, where the mixture is melted, homogenized, and pelletized. The pellets are homogenized, packed and stored.
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Production Process Information
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Production Process Information
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Production Costs Datasheet
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Operating Cost Details
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Production Process Information
Process Consumptions
Labor Requirements
Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
Plant Capital Cost Details
Operating Cost Details
Plant Cost Breakdowns
Plant Capacity Assessment
Process Flow Diagrams
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the HDPE production plant examined
Plant Capital Cost Details
Detailing of fixed capital (ISBL, OSBL & Owner’s Cost), working capital and additional capital requirements
Plant Cost Breakdowns
Breakdown of HDPE process unit (ISBL) costs and infrastructure (OSBL) costs; plant cost breakdown per discipline
Operating Costs Summary
Summary presenting the operating variable costs and the total operating cost of the HDPE production plant studied
Operating Cost Details
Detailing of utilities costs, operating fixed costs and depreciation
Plant Capacity Assessment
Comparative analysis of capital investment and operating costs for different HDPE plant capacities
Production Process Information
Block Flow Diagram, descriptions of process unit (ISBL) and site infrastructure (OSBL)
Process Consumptions
Raw materials and utilities consumption figures, by-products credits, labor requirements
Process Diagrams
Process flow diagrams (PFD), equipment list and industrial site configuration
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