LLDPE from Ethylene and 1-Octene (Similar to SCLAIRTECH)
LLDPE Production Costs Report | Issue A | Q3 2024
| Report Details |
| 350 kta United States-based plant | Q3 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 Linear Low Density Polyethylene (LLDPE) production from polymer grade (PG) ethylene and 1-octene comonomer in the United States, using a solution process similar to NOVA Chemicals SCLAIRTECH. This process uses a tubular reactor and a CSTR operating in series.
The report provides a comprehensive study of LLDPE production and related LLDPE production cost, covering three key aspects: a complete description of the LLDPE production process examined; an in-depth analysis of the related LLDPE plant capital cost (Capex); and an evaluation of the respective LLDPE plant operating costs (Opex).
The LLDPE 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 LLDPE 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 LLDPE 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) Purification and catalyst preparation; (2) Reaction; (3) Distillation; and (4) Finishing.
Purification and catalyst preparation. The cyclohexane solvent, ethylene and 1-octene are sent to fixed-bed adsorption systems to remove water, oxygen and other polar impurities. The catalysts used in the process are based on mixtures of titanium and vanadium compounds in conjunction with aluminum alkyls cocatalysts.
Reaction. Ethylene, 1-octene comonomer and cyclohexane are mixed and pumped to polymerization reactor. The polymerization is carried out in a solution phase, at a temperature above the melting point of the resulting polymer. The reaction system consists of a tubular reactor and a continuous-stirred-tank reactor (CSTR). The low residence time of the reactors enables a high flexibility for grade transitions and versatility for the production of resins across a wide range of densities, melt indexes, and molecular weight distributions. The reactor output stream is fed into separator vessels where unreacted ethylene and comonomers, solvent, and any other volatile matter are separated from the PE. The polymer is sent to the finishing section while the light stream follows to the distillation system.
Distillation. The distillation step comprises five distillation columns in charge of recovering the unreacted ethylene and comonomers; recovering the solvent; purging impurities, such as oligomers (also called grease), catalyst and deactivators residues; and avoiding the buildup of inert components, such as comonomers isomers.
Finishing. The resulting polymer stream is further fed into an extruder, which is used to incorporate the required additives, as well as to pelletize the polymer. The product is then sent to product blending and storage.
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Production Process Information
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Production Process Information
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Production Costs Datasheet
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Operating Cost Details
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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 LLDPE 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 LLDPE 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 LLDPE 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 LLDPE 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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