Impact PP from Propylene and Ethylene (Spheripol)
Polypropylene Production Costs Report | Issue K | 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
It presents the economics of Polypropylene (PP) Impact Copolymer production from polymer grade propylene and ethylene in the United States, using a bulk/gas phase polymerization process similar to LyondellBasell Spheripol and Mitsui Hypol II. This process occurs in loop reactors followed by a gas-phase fluidized-bed reactor, which converts homopolymer to copolymer.
The report provides a comprehensive study of Polypropylene production and related Polypropylene production cost, covering three key aspects: a complete description of the Polypropylene production process examined; an in-depth analysis of the related Polypropylene plant capital cost (Capex); and an evaluation of the respective Polypropylene plant operating costs (Opex).
The Polypropylene 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 Polypropylene 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 Polypropylene 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) Product Separation, Extrusion and Packaging; and (3) Monomers Recovery.
Polymerization. Fresh and recovered propylene, ethylene, and catalyst are fed to the Prepolymerization reactor and to loop reactors. Polymer granules formed in the prepolymerization is sent to two loop reactors operated in series, where the polymerization occurs. Hydrogen is used as a chain terminator to control the length of the polymer chains. The outlet stream from the loop reactors is degassed in a high pressure degasser and subsequently sent to the gas-phase copolymerization reactor to produce impact PP. The reactor consists of a fluidized-bed reactor in which propylene, ethylene and additional hydrogen are added. The product of the gas phase reactor is then conducted to the product separation section.
Product Separation, Extrusion and Packaging. The product from the gas-phase reactor is degassed in a low pressure degasser to separate the unreacted monomers from the polymer. The polymer receives a steam treatment to deactivate the catalyst and is then dried with hot nitrogen. Afterwards, the product is combined with additives and then flows to the pelletizing unit. The pellets are cooled and sent to product blending and storage. The monomer stream recovered from steam treatment vessel is sent to a steam scrubber for water removal, and then routed to the low-pressure propylene scrubber, while the condensate water is sent to drying gas scrubber. In this scrubber, nitrogen used in the nitrogen dryer is recovered, being mostly recycled, with its remainder being purged.
Monomers Recovery. The overhead stream from the Steamer is directed to a Steam Scrubber, that generates a stream rich in monomer, which is sent to the LP Scrubber. The compressor outlet stream is mixed with a gas stream carrying polymer fines from the degasser area, and is fed to the Propylene Scrubber, in which solid polymer is withdrawn from its bottom and propylene enriched stream is recovered in the top. This stream is partly recycled to the Loop Reactors, and the remainder is routed to a nearby plant.
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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 Polypropylene 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 Polypropylene 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 Polypropylene 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 Polypropylene 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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