PP Homopolymer from Propylene (Spheripol)
Polypropylene 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 Polypropylene (PP) Homopolymer production from polymer grade (PG) propylene. The process under analysis uses a bulk phase polymerization process similar to LyondellBasell Spheripol and Mitsui Hypol II. 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 three major sections: (1) Reaction and purification; (2) Polymer degassing and pelletizing; and (3) Monomer recovery.
Reaction and purification. Fresh polymer grade (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, forming a protective shell around the catalyst particle, in order to decrease occurrence of fouling. The reactor and dryers outlets are mixed with hydrogen and routed to two loop reactors in series, where the polymerization takes place. The final product of this step containing spheres of polypropylene, unreacted monomers, catalyst and other impurities, is cooled and sent to treatment.
Polymer degassing and pelletizing. The slurry from the reactor is discharged in two pressure vessels to separate the unreacted monomer 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.
Monomer recovery. The gas from the high-pressure degasser is directly sent to the propylene scrubber. The low-pressure propylene from steam scrubber is washed with an anti-fouling agent before being compressed and sent to the propylene scrubber. In the propylene scrubber, the monomer is separated from polymer residues and recycled to the reaction area. A fraction of the recycle monomer stream is sent to a propylene-propane splitter column (inside the purification area of the propylene supplier, if the plant is part of an integrated petrochemical complex) for purification.
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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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