Homopolymer HDPE from Ethylene (Similar to Advanced SCLAIRTECH)
HDPE Production Costs Report | Issue I | Q2 2024
Report Details |
350 kta United States-based plant | Q2 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 examines the costs related to High Density Polyethylene (HDPE) production from polymer grade (PG) ethylene in the United States. The process examined in this report uses a solution process similar to NOVA Chemicals Advanced SCLAIRTECH. The polymerization is carried out in two continuous-stirred-tank reactors (CSTR)
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) Finishing; and (3) Chemicals Recovery.
Polymerization. The methylpentane solvent and ethylene monomer recycled from distillation columns are mixed with fresh streams and sent to fixed-bed adsorption systems to remove potential catalyst poisons, such as water and oxygen. The reaction temperature is a major determinant of polymer molecular weight, so the solution is sent to a cooler before being fed to the reactors. The exothermic polymerization reaction is carried out in two adiabatic continuous-stirred-tank reactors (CSTR) operating in series. Under the process conditions, the polymer is dissolved in the solvent. The catalyst employed in the process is an advanced Ziegler-Natta catalyst. Since a small amount of the catalyst remains active, a deactivating solution is added to the mixture to terminate the polymerization process.
Finishing. The deactivated solution is first heated by using high pressure steam, and then flashed into an intermediate pressure separator and in a second low pressure separator. In the separators, the unreacted ethylene, impurities, reaction solvent, deactivator solvent and any other volatile matter are separated from the Polyethylene. The resin leaving the low-pressure separator is fed into an extruder, which is used to incorporate the required additives, as well as to pelletize the polymer. The pellets are then stripped with steam to remove any remaining solvent or comonomer. Finally, they are homogenized in blending silos and stored.
Chemicals Recovery. The gas stream from the separators is mixed with the recovered solvent from finishing area and pumped to two distillation columns. There, ethylene and methylpentane solvent are recovered and recycled to purification. Low process steam is generated to be used in the process and heavy impurities are eliminated.
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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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