LLDPE Production from Ethylene and 1-Butene (Similar to UNIPOL)
LLDPE Production Costs Report | Issue F | Q2 2024
Report Details |
450 kta United States-based plant | Q2 2024 | 107 pages | Delivered in PDF |
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 study presents the economics of Linear Low Density Polyethylene (LLDPE) production from polymer grade (PG) ethylene and 1-butene in the United States, using a gas phase process similar to Univation UNIPOL and INEOS INNOVENE. This technology comprises a reaction loop consisting of a fluidized-bed reactor, a compressor and a heat exchanger. Residual hydrocarbons are removed from the product by a propane stream.
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 three major sections: (1) Polymerization; (2) Polymer degassing; and (3) Finishing.
Polymerization. Initially, raw materials are purified, since catalysts used in the process are sensitive to specific impurities. Such feed purification consists, mainly, in removing oxygen and water from ethylene and 1-butene, by means of purification columns and molecular sieves. After purified, the ethylene is polymerized in combination with 1-butene in a reaction loop consisting of a reactor, a compressor and a heat exchanger. The molecular weight of the polymer is controlled by hydrogen gas 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 hydrocarbons are 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 monomers are 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 LLDPE pellets are packed in bags before being stored in warehouses.
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Production Process Information
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Plant Capital Cost Summary
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Production Costs Datasheet
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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
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Updated with Q2 2024 Data
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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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