Production Cost Report
ICC - Is Bespoken: 0
ICC - Main References: ?
ICC - Issue: K
ICC - Volume: 199
ICC - Report ID: 199-K
ICC - Report Location: United States
ICC - Is Popular: 0
ICC - Is Developed: 1
ICC - Title: Impact PP from Propylene and Ethylene (Spheripol)
ICC - Show Overview: 1
ICC - Report Location ID: 1
ICC - Plant Capacity Unit ID: 14
ICC - Volume Reports List: 199-A,199-B,199-C,199-D,199-F,199-H,199-I,199-J,199-N,199-Q,199-S,199-V,199-E,199-G,199-L,199-M,199-O,199-P,199-R,199-T,199-U,199-W,199-X
ICC - Related Reports List: 230-B,230-A,172-A,172-B
ICC - Report Location Code: USA
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ICC - Prices: {"versions":{"1":{"1":"799","2":"799","3":"799"},"2":{"1":"1599","2":"1599","3":"1599"},"3":{"1":"2699","2":"2699","3":"2699"}},"currency":"USD"}
ICC - Plant Capacity Unit Name: kilo metric ton per annum
ICC - Plant Capacity Unit Short Name: kta
ICC - Process Overview Image: //cdn.intratec.us/images/icc/process-overview/199-K.jpg
ICC - Process Overview Text: <h6>Product</h6> <p><b>PP Impact Copolymer</b>. Polypropylene (a.k.a. PP, Polypropene) stands as a thermoplastic polymer comprising 10,000 to 20,000 monomer units, making it a notable contender in the realm of polymer production. In fact, it ranks as the second most widely manufactured commodity plastic, surpassed only by polyethylene. In a qualitative approach, PP is a colorless, translucent to transparent solid with a glossy surface. PP is a versatile, durable, and extremely rugged material. The properties and texture of PP may vary based on the specific manufacturing process employed during its creation. It is known to have good tensile strength despite its lightweight nature. PP has great elasticity, fatigue resistance, and water resistance, along with a higher melting point compared to many other plastics available in the market. Its chemical resistance proves favorable, displaying a good resistance to chemicals, greater scratch resistance when compared to other polyolefins, and good environmental stress cracking resistance. Additionally, PP lends itself well to processes such as injection molding and extrusion and exhibits a low moisture absorption rate.</p> <h6>Raw Materials</h6> <p><b>Propylene</b>. Propylene, the main raw material consumed, is a colorless gas at room temperature. It is a low-boiling, flammable, and highly volatile gas, with molecular formula C3H6. Propylene reacts vigorously with oxidizing materials. It may be mildly irritating to the nose, throat, and respiratory tract; propylene has low acute toxicity from inhalation. PG Propylene has been mainly produced as ethylene manufacturing co-product (via steam cracking of paraffinic hydrocarbons) and by-product of petroleum refining (separation from refinery gas). Most recently, amid a tight propylene market, new and novel lower-cost chemical processes for on-purpose propylene production have emerged.</p> <b>Ethylene</b>. Ethylene is known as a key building block for the petrochemical industry, being one of the largest-volume petrochemical produced worldwide. It is widely used as chemical intermediate in the production of several end products, including plastics, resins and fibers. Ethylene is largely produced by thermal cracking of petroleum-based feedstocks, in the presence of steam. It is stored in a liquid state under high pressure or at low temperatures. However, ethylene is, most of times, directly supplied to its consumers.</p> <b>Chemicals</b>. </p>
ICC - Process Schematic Image: //cdn.intratec.us/images/icc/process-schematics/199-K.jpg
ICC - Process Schematic Text: <p>The process under analysis comprises three major sections: (1) Polymerization; (2) Product Separation, Extrusion and Packaging; and (3) Monomers Recovery.</p><p>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.</p><p>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.</p><p>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.</p>
ICC - Short Description: 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.
ICC - Main Product: Polypropylene
ICC - Plant Capacity: 350.00
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Impact PP from Propylene and Ethylene (Spheripol)

Polypropylene Production Costs Report | Issue K | Q3 2024

Production Cost Report

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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.

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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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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

Costs in Different Countries Add-on

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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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This report examines the costs related to Polypropylene (PP) Random Copolymer production from polymer grade (PG) propylene and ethylene. The cost analysis is based on a plant located in the United States, using a gas phase polymerization process in a multi-zone circulating reactor (MZCR), similar to LyondellBasell Spherizone.

Details: 350 kta United States-based plant   |   Q3 2024   |   107 pages   |   Issue P   From $799 USD

The cost analyses presented in this report target a 350 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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This report analyses the economics of Polypropylene (PP) Random Copolymer production from polymer grade (PG) propylene and ethylene in the United States. The process examined in this report is similar to INEOS INNOVENE and JPP HORIZONE, which uses a horizontal stirred-bed reactor.

Details: 350 kta United States-based plant   |   Q3 2024   |   107 pages   |   Issue R   From $799 USD

The cost analyses presented in this report target a 350 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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This report presents the economics of a naphtha-based steam cracker, equipped with an electricity cogeneration unit. In this process, naphtha is thermally cracked at low severity conditions, maximizing propylene to Ethylene ratio. The analysis is based on a plant located in Germany.

Details: 800 kta Germany-based plant   |   Q3 2024   |   107 pages   |   Issue A   From $799 USD

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Details: 1,200 kta United States-based plant   |   Q3 2024   |   107 pages   |   Issue B   From $799 USD

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Details: 550 kta United States-based plant   |   Q3 2024   |   107 pages   |   Issue B   From $799 USD

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