Production Cost Report
ICC - Is Bespoken: 0
ICC - Main References: ?
ICC - Issue: I
ICC - Volume: 198
ICC - Report ID: 198-I
ICC - Report Location: United States
ICC - Is Popular: 0
ICC - Is Developed: 1
ICC - Title: Homopolymer HDPE from Ethylene (Similar to Advanced SCLAIRTECH)
ICC - Show Overview: 1
ICC - Report Location ID: 1
ICC - Plant Capacity Unit ID: 14
ICC - Volume Reports List: 198-A,198-C,198-D,198-E,198-F,198-H,198-J,198-L,198-B,198-G,198-K
ICC - Related Reports List: 172-A,172-B
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-I.jpg
ICC - Process Overview Text: <h6>Product</h6> <p><b>HDPE</b>. HDPE (a.k.a. High Density Polyethylene) is one of the three main types of polyethylene, figuring among the most used polymers worldwide. It is the most widely used polyethylene resin. HDPE may be either ethylene homopolymer or a copolymer of ethylene and alpha-olefins (1-hexene, 1-butene). Polyethylene is considered to be high density when having density greater than 0.94 g/cm³. Despite having density only marginally higher than that of low-density polyethylene (LDPE), HDPE presents larger strength-to-density ratio, due to its little branching and consequent stronger intermolecular forces. The high demand for polyethylene is in large part due to a combination of the availability of ethylene raw material, its relatively low cost and a wide variety of applications.</p> <h6>Raw Materials</h6> <p><b>Ethylene</b>. Ethylene is known as a key building block for the petrochemical industry, being one of the largest-volume petrochemical produced worldwide. It is widely used as chemical intermediate in the production of several end products, including plastics, resins and fibers. Ethylene is largely produced by thermal cracking of petroleum-based feedstocks, in the presence of steam. It is stored in a liquid state under high pressure or at low temperatures. However, ethylene is, most of times, directly supplied to its consumers.</p> <b>Chemicals</b>. </p>
ICC - Process Schematic Image: //cdn.intratec.us/images/icc/process-schematics/198-I.jpg
ICC - Process Schematic Text: <p>The process under analysis comprises three major sections: (1) Polymerization; (2) Finishing; and (3) Chemicals Recovery.</p><p>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. </p><p>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.</p><p>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.</p><p></p>
ICC - Short Description: 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)
ICC - Main Product: HDPE
ICC - Plant Capacity: 350.00
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Homopolymer HDPE from Ethylene (Similar to Advanced SCLAIRTECH)

HDPE Production Costs Report | Issue I | Q2 2024

Production Cost Report

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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.

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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

Other HDPE Production Cost Reports

Homopolymer HDPE from Ethylene (Similar to Spherilene)

It presents the economics of High Density Polyethylene (HDPE) production from polymer grade (PG) ethylene in the United States. The process examined in this report uses a gas phase process similar to LyondellBasell Spherilene. The polymerization is conducted in a single fluidized-bed reactor.

Details: 450 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue G   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   |   Q2 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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Other Related Production Cost Reports

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   |   Q2 2024   |   107 pages   |   Issue A   From $799 USD

The cost analyses presented in this report target a 800 kta (kilo metric ton per annum per annum) Germany-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.

Ethylene Production from Ethane

This report presents the economics of Polymer Grade (PG) Ethylene production from ethane in the United States. In the process under analysis, ethane is thermally cracked in pyrolysis furnaces through the use of steam, yielding Ethylene. A hydrogen-rich gas is generated as by-product.

Details: 1,200 kta United States-based plant   |   Q2 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.

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