Production Cost Report
ICC - Is Bespoken: 0
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ICC - Issue: S
ICC - Volume: 199
ICC - Report ID: 199-S
ICC - Report Location: United States
ICC - Is Popular: 0
ICC - Is Developed: 1
ICC - Title: PP Random Copolymer from Propylene and Ethylene (Novolen)
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-E,199-F,199-G,199-H,199-I,199-J,199-K,199-L,199-M,199-N,199-O,199-P,199-Q,199-R,199-T,199-U,199-V,199-W,199-X
ICC - Related Reports List: 230-A,230-B,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-S.jpg
ICC - Process Overview Text: <h6>Product</h6> <p><b>PP Random 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-S.jpg
ICC - Process Schematic Text: <p>The process under analysis can be separated in three different areas: purification & reaction; resin degassing & pelleting; and vent recovery.</p><p>Purification & reaction. Fresh polymer grade (PG) propylene is sent to fixed bed dryers for removal of water and other polar impurities. Purified propylene, fresh ethylene and a recycle stream from the vent recovery system are then continuously fed to a mechanically stirred reactor that uses a helically shaped agitator to keep the polymer bed well mixed and prevent particle agglomeration. The polymerization temperature is controlled by flash evaporating recycle gas inside the reactor.</p><p>Resin degassing & pelleting. The outlet reactor stream is directed to a discharge vessel where accompanying reactor gas (carrier gas) is recovered at low-pressure conditions. Polymer powder is sent to a purge vessel, while the carrier gas goes through a cyclone and a filter and is finally sent to recovery. Nitrogen is used to remove residual monomer from the polymer powder and then is also sent to recovery. The polymer powder then goes to a screw extruder, where polymer powder and additives are melted, compounded and homogenized. After being extruded, the pellets are carried to a centrifugal dryer.</p><p>Vent recovery. The carrier gas is compressed and a portion is sent back to the reactor. The remaining portion is directed to the monomer supply unit in order to recover propylene. The purge gas is separated in a membrane unit into a nitrogen stream and a propylene-rich stream. The nitrogen stream is recycled to the process, while the monomer-rich stream goes to the propylene supply unit for purification.</p>
ICC - Short Description: This study presents 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 Lummus Technoloy's Novolen, which uses vertical stirred-bed reactors.
ICC - Main Product: Polypropylene
ICC - Plant Capacity: 400.00
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PP Random Copolymer from Propylene and Ethylene (Novolen)

Polypropylene Production Costs Report | Issue S | Q2 2024

Production Cost Report

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400 kta United States-based plant   |   Q2 2024   |   107 pages   |   Delivered in PDF

This report presents a cost analysis of a 400 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

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

Other Polypropylene Production Cost Reports

PP Homopolymer from Propylene (Spheripol)

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.

Details: 350 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue A   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.

PP Homopolymer from Propylene (BORSTAR)

This study presents the economics of Polypropylene (PP) Homopolymer production from PG propylene. The process under analysis uses a hybrid (slurry/gas) polymerization process similar to the Borealis BORSTAR process. The economic analysis assumes a plant constructed in the United States.

Details: 400 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue B   From $799 USD

The cost analyses presented in this report target a 400 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.

PP Homopolymer from Propylene (Spherizone)

This report examines the costs related to Polypropylene (PP) Homopolymer production from polymer grade (PG) propylene, using a gas phase polymerization process similar to LyondellBasell Spherizone. The reaction occurs in a multi-zone circulating reactor (MZCR). The economic analysis performed assumes a plant located in the United States.

Details: 350 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue C   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.

PP Homopolymer from Propylene (UNIPOL)

This study presents the economics of Polypropylene (PP) Homopolymer production from polymer grade (PG) propylene. The process examined in this report is similar to Grace UNIPOL process. In this process, gaseous propylene is polymerized to PP in fluidized-bed reactors (FBRs). The economic analysis performed assumes a plant located in the United States.

Details: 400 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue D   From $799 USD

The cost analyses presented in this report target a 400 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.

PP Homopolymer from Propylene (INNOVENE)

This report analyses the economics of Polypropylene (PP) Homopolymer production from polymer grade (PG) propylene in a plant assumed to be located in the United States. In this process, gaseous PG propylene is polymerized in horizontal agitated reactors connected in series. The process examined in this report is similar to INEOS INNOVENE and JPP HORIZONE.

Details: 350 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue E   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.

PP Homopolymer from Propylene (Novolen)

This study presents the economics of Polypropylene (PP) Homopolymer production from polymer grade (PG) propylene in the United States. In this process, gaseous PG propylene is polymerized in vertical stirred-bed reactors. The process examined in this report is similar to Lummus Technology's Novolen.

Details: 400 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue F   From $799 USD

The cost analyses presented in this report target a 400 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.

Impact PP from Propylene and Ethylene (Spherizone)

It presents the economics of Polypropylene (PP) Impact Copolymer production from polymer grade (PG) propylene and ethylene in the United States, using a gas phase polymerization process similar to LyondellBasell Spherizone process. This process employs two multi-zone circulating reactors (MZCRs) connected in series, with PP Homopolymer as intermediate.

Details: 350 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue G   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.

Impact PP from Propylene and Ethylene (UNIPOL)

This report presents the economics of Polypropylene (PP) Impact Copolymer production from polymer grade (PG) propylene and ethylene in the United States. The process examined in this report is similar to Grace UNIPOL process. This process occurs in fluidized-bed reactors (FBRs) connected in series.

Details: 400 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue H   From $799 USD

The cost analyses presented in this report target a 400 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 study presents the economics of Polypropylene (PP) Impact Copolymer production from polymer grade (PG) propylene and ethylene in the United States. This process is similar to INEOS INNOVENE and JPP HORIZONE processes. The reaction occurs in horizontal agitated reactors connected in series.

Details: 350 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue I   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.

Impact PP from Propylene and Ethylene (Novolen)

This report examines the costs related to Polypropylene (PP) Impact Copolymer production from polymer grade (PG) propylene and ethylene in the United States. The process examined in this report is similar to Lummus Technology's Novolen process. This process occurs in vertical fluidized-bed reactors connected in series.

Details: 400 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue J   From $799 USD

The cost analyses presented in this report target a 400 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.

Impact PP from Propylene and Ethylene (Spheripol)

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.

Details: 350 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue K   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.

Impact PP from Propylene and Ethylene (BORSTAR)

This study presents the economics of Polypropylene (PP) Impact Copolymer production from polymer grade (PG) propylene and ethylene in the United States, using a slurry/gas phase polymerization process similar to Borealis BORSTAR process. This process is divided in two modules. The first is applied for homopolymer and the second is added to produce the copolymer.

Details: 350 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue L   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.

Impact PP from Propylene and Ethylene (Slurry Process)

This report examines the costs related to Polypropylene (PP) Impact Copolymer production from polymer grade (PG) propylene and ethylene in the United States, using a typical improved slurry phase polymerization process.

Details: 400 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue M   From $799 USD

The cost analyses presented in this report target a 400 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.

PP Random Copolymer from Propylene and Ethylene (Spheripol)

This report presents the economics of Polypropylene (PP) Random Copolymer production from polymer grade (PG) propylene and ethylene. The economic analysis assumes a plant located in the United States, using a bulk phase polymerization process in loop reactors, similar to LyondellBasell Spheripol and Mitsui Hypol II.

Details: 400 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue N   From $799 USD

The cost analyses presented in this report target a 400 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.

PP Random Copolymer from Propylene and Ethylene (BORSTAR)

This study presents the economics of Polypropylene (PP) Random Copolymer production from PG propylene and ethylene. The analysis concerns a plant constructed in the United States, using an hybrid (slurry/gas) polymerization process similar to Borealis BORSTAR.

Details: 450 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue O   From $799 USD

The cost analyses presented in this report target a 450 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.

PP Random Copolymer from Propylene and Ethylene (Spherizone)

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   |   Q2 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.

PP Random Copolymer from Propylene and Ethylene (UNIPOL)

It presents 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 Grace UNIPOL process, which uses fluidized-bed reactors (FBRs).

Details: 400 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue Q   From $799 USD

The cost analyses presented in this report target a 400 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.

PP Random Copolymer from Propylene and Ethylene (INNOVENE)

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   |   Q2 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.

PP Homopolymer from Propane (CATOFIN PDH / Spheripol PP)

In this process, propane is first dehydrogenated in fixed-bed reactors, using a process that is similar to Lummus CATOFIN, yielding polymer grade propylene. PG propylene is then polymerized using 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.

Details: 350 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue T   From $1,499 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.

PP Homopolymer from Propane (CATOFIN PDH / Novolen PP)

This report examines the costs related to Polymer Grade (PG) Propylene production from propane in the United States. In this process, polymer grade (PG) propylene is first produced via dehydrogenation of propane using fixed-bed reactors, in a process similar to Lummus CATOFIN. Then propylene is subjected to a gas phase polymerization in vertical stirred-bed reactors to produce polypropylene, in a process similar to Lummus Technology's Novolen.

Details: 400 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue U   From $1,499 USD

The cost analyses presented in this report target a 400 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.

PP Homopolymer from Propane (Oleflex PDH / Spheripol PP)

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.

Details: 350 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue V   From $1,499 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.

PP Homopolymer from Propane (Oleflex PDH / UNIPOL PP)

This study presents the economics of Polypropylene (PP) Homopolymer 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. Gaseous PG propylene is then polymerized to PP in fluidized-bed reactors (FBRs), similarly to the Grace UNIPOL process. The economic analysis performed assumes a plant located in the United States.

Details: 400 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue W   From $1,499 USD

The cost analyses presented in this report target a 400 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.

PP Homopolymer from Propane (STAR PDH / Spheripol PP)

This study presents the economics of Polypropylene (PP) Homopolymer production from propane. Polymer grade (PG) propylene is first produced via a two-step propane dehydrogenation process (steam reforming/oxyreaction), similarly to the Uhde STAR process. 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.

Details: 350 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue X   From $1,499 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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Details: 350 kta United States-based plant   |   Q2 2024   |   107 pages   |   Issue A   From $799 USD

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