Production Cost Report
ICC - Is Bespoken: 0
ICC - Main References: ?
ICC - Issue: A
ICC - Volume: 198
ICC - Report ID: 198-A
ICC - Report Location: United States
ICC - Is Popular: 0
ICC - Is Developed: 1
ICC - Title: Bimodal HDPE from Ethylene and 1-Butene (Similar to Hostalen)
ICC - Show Overview: 1
ICC - Report Location ID: 1
ICC - Plant Capacity Unit ID: 14
ICC - Volume Reports List: 198-C,198-D,198-E,198-F,198-H,198-I,198-J,198-L,198-B,198-G,198-K
ICC - Related Reports List: 175-C,175-B,256-A,172-B,172-A
ICC - Report Location Code: USA
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ICC - Prices: {"versions":{"1":{"1":"799","2":"799","3":"799"},"2":{"1":"1599","2":"1599","3":"1599"},"3":{"1":"2699","2":"2699","3":"2699"}},"currency":"USD"}
ICC - Plant Capacity Unit Name: kilo metric ton per annum
ICC - Plant Capacity Unit Short Name: kta
ICC - Process Overview Image: //cdn.intratec.us/images/icc/process-overview/198-A.jpg
ICC - Process Overview Text: <h6>Product</h6> <b>Bimodal HDPE</b></p></b></p> <h6>Raw Materials</h6> <p><b>Ethylene</b></p>, <p><b>Chemicals</b></p>, <p><b>1-Butene</b></p>, <p><b>n-Hexane</b></p>
ICC - Process Schematic Image: //cdn.intratec.us/images/icc/process-schematics/198-A.jpg
ICC - Process Schematic Text: <p>The process under analysis comprises three major sections: (1) Polymerization; (2) Purification; and (3) Finishing.</p><p>Polymerization. In the first area, a catalyst suspension for the polymerization is prepared. Fresh and recovered monomers (ethylene and 1-butene), magnesium and titanium chloride, used as catalyst, suspended in hexane are continuously fed to the first reactors, forming a slurry which is homogenized by the agitators. Hydrogen is also used, as the chain terminator. The monomer molecules get in contact with the catalyst suspended in the slurry and form the polymer particles. As the particles precipitate, they do not dissolve in the slurry. Most of the polymerization reaction occurs continuously in the first two reactors. The suspension from the first reactor is pumped to the second reactor and subsequently, from the second reactor to the post-reactor, where the rest of the ethylene is converted into HDPE. </p><p>Purification. The slurry is directed to a decanter centrifuge where it is separated into a liquid and a solid fraction. The hexane moist HDPE powder is fed to a fluidized-bed dryer operated with hot nitrogen, in which the hexane is evaporated. The powder flow is passed through a silo, countercurrently to hot nitrogen and slightly superheated steam, in such a way that the residual hexane is removed, and catalysts residues are destroyed. Hexane and butene from off-gases are recovered and recycled to the Reactors.</p><p>Finishing. The dried polymer powder and a mix of stabilizers and other additives pass through an extrusion and pelletizing system, is packed and sent to storage facilities.</p>
ICC - Short Description: This report presents the economics of Bimodal High Density Polyethylene (HDPE) production from polymer grade (PG) ethylene and 1-butene in the United States, using a slurry process similar to LyondellBasell Hostalen and Mitsui CX. The polymerization is carried out in three CSTRs using hexane as diluent and a high-activity Ziegler catalyst system.
ICC - Main Product: HDPE
ICC - Plant Capacity: 350.00
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ICC - Table Count: {"versions":{"1":"22","2":"28","3":"34"}}

Bimodal HDPE from Ethylene and 1-Butene (Similar to Hostalen)

HDPE Production Costs Report | Issue A | Q4 2024

Production Cost Report

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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.

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Production Process Information

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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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This report analyses the economics of High Density Polyethylene (HDPE) production from polymer grade (PG) ethylene in the United States. The process examined in this report is similar to Univation UNIPOL and INEOS INNOVENE G. In this process, ethylene is polymerized in the gas-phase in a reaction loop consisting of a fluidized-bed reactor, a compressor and a heat exchanger.

Details: 450 kta United States-based plant   |   Q4 2024   |   107 pages   |   Issue H   From $799 USD

The cost analyses presented in this report target a 450 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

HDPE from Ethylene and 1-Butene (Similar to Spherilene)

This report analyses the economics of 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 gas-phase polymerization in a single reactor similar to LyondellBasell Spherilene S.

Details: 450 kta United States-based plant   |   Q4 2024   |   107 pages   |   Issue J   From $799 USD

The cost analyses presented in this report target a 450 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

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Ethylene Production from Naphtha (Low Severity Steam Cracking)

This report presents the economics of a naphtha-based steam cracker, equipped with an electricity cogeneration unit. In this process, naphtha is thermally cracked at low severity conditions, maximizing propylene to Ethylene ratio. The analysis is based on a plant located in Germany.

Details: 800 kta Germany-based plant   |   Q4 2024   |   107 pages   |   Issue A   From $799 USD

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Details: 1,200 kta United States-based plant   |   Q4 2024   |   107 pages   |   Issue B   From $799 USD

The cost analyses presented in this report target a 1,200 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

1-Butene Production from Ethylene

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Details: 50 kta United States-based plant   |   Q4 2024   |   107 pages   |   Issue B   From $799 USD

The cost analyses presented in this report target a 50 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

1-Butene from Raffinate-2 (Extractive Distillation)

In this report, the economic analysis concerns a plant located in the United States, producing 1-Butene using a conventional industrial approach for extractive distillation of raffinate-2, which also generates raffinate-3 as by-product.

Details: 120 kta United States-based plant   |   Q4 2024   |   107 pages   |   Issue C   From $799 USD

The cost analyses presented in this report target a 120 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

Hexane Production

This report presents the economics of Hexane production from crude glycerol in the United States. In this process, crude glycerol is reformed in aqueous phase, generating a range of hydrocarbons and oxygenated compounds, including Hexane. Part of these compounds undergoes aldol condensation and hydrodeoxygenation, raising Hexane yield.

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The cost analyses presented in this report target a 300 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

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