Homopolymer HDPE from Ethylene (Similar to MarTECH Loop Slurry)
HDPE Production Costs Report | Issue F | Q4 2024
| Report Details |
| 450 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 450 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 High Density Polyethylene (HDPE) production from polymer grade (PG) ethylene in the United States, using a slurry loop process similar to Chevron Phillips MarTECH and INEOS INNOVENE S. In this process, the monomers are polymerized in a single loop 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; and (3) Separation; and (4) Finishing.
Feed Preparation. This area comprises a catalyst activation system (fluidized-bed activator) and fixed bed treaters for purification of ethylene monomer and isobutane, used as diluent in the polymerization.
Polymerization. In a loop reactor, the monomers and the catalyst suspension are mixed and circulated - as the polymer particles precipitate, they do not dissolve in the slurry. Cooling water in reactor jacket removes reaction heat. The slurry is continuously discharged to a flash chamber, for removing residual monomers.
Separation. The flashed stream passes through a bag filter for polymer fines removal. The fines are sent to the purge column. In the purge column, the residual hydrocarbons are stripped from the polymer product with heated nitrogen. The separated gaseous hydrocarbon streams from flash chamber and purge column are sent to purification in order to recover monomers and diluent, reused in the process.
Finishing. The polymer powder from the purge column, additives and antiblocks are fed to a pelletizing system, where the mixture is melted, homogenized, and pelletized. The pellets are homogenized in blending silos and stored.
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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.
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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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