Bimodal HDPE from Ethylene and 1-Butene (Similar to Hostalen)
HDPE Production Costs Report | Issue A | 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, 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.
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 three major sections: (1) Polymerization; (2) Purification; and (3) Finishing.
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.
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.
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.
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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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