PP Homopolymer from Propane (Oleflex PDH / Spheripol PP)
Polypropylene Production Costs Report | Issue V | 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 study presents the economics of Polypropylene production from propane. In this two-step process, first polymer grade (PG) propylene is produced via dehydrogenation of propane, carried out in a moving-bed reactor, similarly to UOP Oleflex. PG propylene is then polymerized using a bulk phase polymerization process similar to LyondellBasell Spheripol. The economic analysis performed assumes a plant located in the United States.
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 four major sections: (1) Propane Dehydrogenation; (2) Propylene Purification; (3) Polymerization; and (4) Polymer Degassing and Pelletizing.
Propane Dehydrogenation. Fresh and recycled propane are fed to a depropanizer column for heavy impurities removal and then heated to the reaction temperature in a charge heater. The dehydrogenation reaction takes place on moving bed reactors across multiple stages, which operate in a continuous mode. In this process, a continuous catalyst regenerator (CCR) unit is used to purge the coke accumulated on the surface of the platinum-based catalyst during the reaction.
Propylene Purification. The reactor effluent is compressed, dried and sent to a low-temperature separation system (cold box) for the removal of a hydrogen-rich stream. Subsequenty. light hydrocarbons and hydrogen traces are removed in a deethanizer column and PG propylene is obtained in a propane-propylene (P–P) splitter.
Polymerization. PG propylene is sent to fixed bed dryers for removal of water and other catalyst poisons, and to the prepolymerization reactor. The catalyst and hydrogen are also fed to this reactor. The reactor and dryers outlets are mixed with hydrogen and routed to two loop reactors in series, where the polymerization takes place.
Polymer Degassing and Pelletizing. The slurry from the reactor containing spheres of polypropylene, unreacted monomer, catalyst and other impurities is discharged in a degassing system to separate the unreacted monomer from the polymer. The gas from the degassing sent to a monomer recovery area before being recycled to the reaction area. A fraction of the recycle monomer stream is sent to a propylene-propane splitter column for purification. The degassed polymer is combined with additives and then flows to the pelletizing unit before being sent to product blending and storage.
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Production Process Information
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Production Process Information
Process Consumptions
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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 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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Details: 450 kta United States-based plant | Q3 2024 | 107 pages | Issue O From $799 USD
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