Homopolymer HDPE from Ethylene (Similar to UNIPOL)
HDPE Production Costs Report | Issue H | 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 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.
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) Polymer degassing; and (3) Finishing.
Polymerization. Initially, ethylene monomer is purified for removal of oxygen and water, which may cause catalyst deactivation. Purification is accomplished by means of columns and molecular sieves. Ethylene is then polymerized in a reaction loop consisting of a reactor, a compressor and a heat exchanger. The molecular weight of the polymer is controlled by hydrogen addition, while the polymerization rate is controlled by the catalyst feed rate. Polyethylene granules are removed from the reactor and directed to a purge bin downstream.
Polymer degassing. In the purge bin, residual monomer is stripped with nitrogen. The purged gas is sent to vent recovery, while the polymer powder is directed to the pelletizing and finishing section downstream. In the vent recovery, unreacted monomer is condensed and pumped back to the reactor, while the uncondensed gas is purged.
Finishing. The polymer powder from the purge bin and a mix of additives are fed to a pelletizing system, where the mixture is melted, homogenized, and pelletized. Subsequently, the HDPE pellets are packed in bags before being stored in warehouses.
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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 | Q4 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 | 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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